Tender Enquiry No HMB/CED/PUR/99/04/10/017/LTE-060 - Heavy ...

ISO 9001 Company 

Heavy Engineering Corporation Limited 

(A Govt. of India Enterprise) 

Heavy Machine Building Plant 

(Purchase Department/ MM Division) 

TENDER DOCUMENT 

PROCUREMENT OF ELECTRICS 

FOR COKE PUSHER 

PURCHASE DEPTT. / MM DIVISION 

HEAVY MACHINE BUILDING PLANT 

HEAVY ENGINEERING CORPORATION LIMITED 

P.O.-DHURWA, RANCHI 

Page 1 of 100 

----------------------------------------------------------------------------------------------------------------- 

HEAVY ENGINEERING CORPORATION LIMITED, DHURWA, RANCHI - 834004 

PHONE: 0651 2401278, FAX: 0651 2401166, EMAIL: pksingh@hecltd.com






Tender Enq.No.HMBP/PUR/2011/961723/EL-3405 Dated: 14.08.2012 

Enquiry Schedule 

Due Date of Tender opening: 30.08.2012 

Scope of Work: This tender specification calls for turnkey execution of the job 

covering the design, engineering, manufacture, supply FOR HMBP stores 

at Ranchi, receipt of material from purchaser‟s store at DSP, 

transportation from purchaser‟s store at DSP to coke oven site, handling, 

storage and re-conservation at DSP site, erection, testing, commissioning 

of electrics with standard accessories and attachment as covered in this 

specification. Demonstration of the proper functioning of the electrical 

system during performance guarantee test of the equipment in a 

coordinated and integrated manner as per the relevant clauses of this 

specification. 

QUALIFYING CRITERIA: 

1) The tenderer should have carried out electrical work related to steel plant equipment including 

VFD & PLC in past, covering design, engineering, supply, erection, testing & 

commissioning. The claim should be substantiated with submission of documentary 

evidence including performance certificate from the users/customers. 

2) The annual turnover of the tenderer shall be minimum 3 cores in last three consecutive 

financial years. Tenderer shall submit audited balance sheet for last three years. 

Terms and Conditions: 

1) The offer must be prepared taking reference to the detailed technical specifications & other details in the 

enclosed DAP-203/12M 

2) Please submit your quotation strictly in three part system i.e.:- 

a. Techno-commercial bid-Part I (This Techno Commercial bid shall be confirming all technical 

specification, commercial terms & conditions and price format with price column blanked ( Unpriced ). The 

price format should contain item wise list of items for which the price has been quoted.) 

b. Price Bid -Part II (This part will comprise price format duly filled in) and 

c. Earnest Money Deposition (EMD) -Part III (This part will contain only DD / Bank guarantee in favor of 

HEC Limited Ranchi-4, for Earnest Money deposit.) 


----------------------------------------------------------------------------------------------------------------- 








3) a. The technical and commercial aspects to be sealed in a separate envelope super scribing Part-I 

on it .The Price bid to be super scribed as Part – II and EMD to be super scribed as Part-III. 

b. All the three bids i.e. Part-I, Part II & Part III shall be in separate sealed covers clearly super 

scribing on the top of each envelope the relevant part number, tender reference number with date 

and due date of opening. 

c. All the three bids i.e. Part-I, Part II & Part III shall be enclosed in one envelope. This envelop shall 

also be super scribed on the top with relevant tender no. and due date of opening. 

4) The Payment Terms shall be as under: 

“90% of the total value of supply part along with hundred percent taxes & duties shall be released through 

Cheque/RTGS within 60 days of receipt of materials complete in all respect along with Guarantee 

Certificate, Test 

Certificate, Inspection Certificate (to be issued by HEC), EDGP (if applicable), Original Invoice, 10% PBG 

(Performance Bank Guarantee) to be valid till full guarantee period from any nationalized bank only in 

HEC’s format and all the drawings and documents as per enquiry specifications. “ 

“Balance 10% of the value of supply part along with the erection and commissioning charges shall be 

released through Cheque/RTGS within 30 days from the date of issue of Commissioning Certificate by 

HEC/Customer “ 

5) Guarantee Clause: The materials supplied shall be guaranteed for 12 months from the date of 

commissioning or 18 months from receipt of material whichever is earlier. 

6) Liquidated Damages (L.D):For late delivery, the L.D. @0.5% per week limited to 10% maximum shall 

be levied on the order value. 

7) Place and Time of submission of quotation: 

Place: Purchase Deptt./HMBP/HEC Limited, Dhurwa, Ranchi – 834 004. 

Date & Time of receipt of tender: 30.08.2012 Upto 1.00 P.M. 

Date & Time of opening of tender: 30.08.2012 at 3.00 P.M. 

8) EMD of 2% of the quoted price shall be submitted in separate sealed cover. The E.M.D. shall be 

submitted in the form of Demand draft / Bank Guarantee from any nationalized bank and in favor of Heavy 

Engineering Corporation Limited payable at Ranchi. The firm shall mention about the submission of 

EMD in their techno-commercial bid indicating DD No./Bank Guarantee No., Date etc. BUT THE 

AMOUNT OF D.D. /VALUE OF BANK GUARRANTEE SHALL NOT BE MENTIONED IN THE TECHNO- 

COMMERCIAL BID. IT MAY PLEASE BE NOTED THAT EMD SHALL BE REFUNDED TO THE 

UNSUCCESSFUL TENDERERS. 

9) Security Deposit: The successful tenderer will have to deposit Security deposit for 5% of the basic order 

value (in form of bank guarantee) within 30 days time after placement of order .The validity of security 

deposit shall be up to receipt of last consignment . 

10) Performance Bank Guarantee (PBG): The successful tenderer will have to furnish PBG of 10% of 

the Basic order value of purchase order valid till full guarantee period from any nationalized Bank 

only in HEC's Format . 

11) Schedule of Tender receipt by 30.08.2012 up to 1.00 PM. Opening of Tender on 30.08.2012, at 

3.00PM, TENDERS must be submitted in sealed cover with Tender No. and the Due date super scribed on 

it failing which Tenders may be ignored. 

12) The rate quoted shall be firm and the prices quoted must be on FOR: Destination i.e. 

Stores/HMBP/HEC Ltd RANCHI - 4 Basis including packing, forwarding, freight & insurance charges. 


----------------------------------------------------------------------------------------------------------------- 








13) The Price quoted by the tenderer should be exclusive of sales tax. The rate and nature of sales tax 

applicable should be shown separately. Sales tax will be paid to the seller at the rate at which it is liable to 

be assessed or has actually been assessed on the date of supply provided the transaction of sale is legally 

liable to sales tax and within the delivery period. Any change on the taxes & duty structure beyond the 

delivery period will not be considered by HEC. 

14) The rates quoted must be firm and offer‟s validity for acceptance must be valid for minimum 04 

months from the date of opening of tender. 

15) Quotations erased or over written are likely to be rejected unless all corrections are authenticated with 

the tenderer's signature. 

16) Delivery date offered must be specified and guaranteed. Delivery within 2 to 3 Months is preferred. 

17) Full particulars i.e. specification, literature and / or drawing wherever applicable should be submitted 

along with the quotation. The brand and 'Make' name must be indicated. 

18) The Corporation does not pledge itself to accept the lowest or any tender and reserves to itself the right 

of accepting the whole or any part of tender or portion of the quantity offered and you shall supply the same 

at the rate quoted. 

19) Supplies will be subject to Inspection by our Inspection wing / or inspection agencies prescribed by us. 

20) Order placed as a result of this tender will be subject to the Corporation's General Terms and 

Conditions of contract which can be down loaded from our website (www.hecltd.com) 

21) Corporation reserves the right to call for and examine at any time the books of accounts and other 

documents and papers of the firm for the purpose of ascertaining whether any excess payments has been 

made or the firm likely to be received / received undue benefit out of execution of the particular contract. 

22) Delivery: The time for and the date of delivery of the Stores stipulated in the acceptance of tender shall 

be deemed to be the essence of the contract and delivery must be completed not later than the dates 

specified therein. Otherwise: 

a) The purchaser to recover from the contractor a sum of 0.5 % per week (completed week) of the price of 

The stores (up to maximum 10 %) as liquidated damages, which the contractor has failed to deliver as 

Aforesaid or 

b) The purchaser may procure the undelivered stores / similar items from elsewhere, without notice to the 

Contractor at the risk of the contractor without canceling the contract in respect of the consignment not yet 

due for delivery or, 

c) To cancel the contract or a portion thereof. 

23. Income Tax Clearance Certificate - All tenderers shall submit along with their tender an Income Tax 

Clearance Certificate duly countersigned by the Income Tax Officer of the circle concerned under the seal 

of the office. Copy of Permanent Account No. (PAN) (Of Income Tax) to be enclosed with the bid. 

24. There is no obligation on our part to accept delayed / late tenders. Tenders received after the due date 

of opening are liable to be summarily rejected. 

26. The rates quoted shall also be inclusive of embossing on the material. The Ownership namely HMBP / 

FFP / HMTP should be at a predominant place of the material to a size / thickness upon the volume of the 

material. 

25. Way Bills/ Road Permit: No consignment from outside the state of Jharkhand shall be dispatched by the 

Supplier without a valid way bill / Road Permit, to be issued by PURCHASER. 

26. The Supplier shall produce documentary evidence as may be called for by PURCHASER in respect of 

taxes, duties etc. paid by the Supplier. 

27. Termination of Order:i. 

The order can be terminated if the supplier fails to deliver the goods in time. 

ii. Any other reason due to which company thinks it fit to terminate the order. 

iii. In the event of the termination of the contract in part/ full the company can get the work 

Completed from any other agency/ departmentally at the risk and cost of the supplier. 

28. MODE OF DESPATCH 


----------------------------------------------------------------------------------------------------------------- 








By road to the consignee: In-charge, Stores, HMBP, HEC Ltd, Ranchi. For the consignments to be 

dispatched by Road, the supplier shall ensure that the following are observed by them: 

i) All dispatches must be affected only on receipt of written dispatch clearance from PURCHASER. 

ii) You shall dispatch all the materials consigned to In-charge Stores, HMBP, HEC Ltd, Ranchi 

iii) Care shall be taken to avoid damages during transit to ensure that all packages are firmly 

secured. 

29. PACKING, FORWARDING AND SHIPMENT 

a) The Supplier shall notify the Purchaser of the date of each shipment from his works, and the expected 

date of arrival at the site for the information. 

30. OTHER TERMS AND CONDITIONS 

Other terms and conditions which are not mentioned above shall be as per General Terms and 

Conditions of Contract of the Corporation which can be downloaded from our website 

(www.hecltd.com). 

Important: While submitting tender please mentioned your Registration No. with HEC as a registered 

vendor with valid paper. If not please get registered your firm with HEC Limited immediately. 

(P.K.Singh) 

Sr.DGM/PUR/HMBP/HEC Ltd. 


----------------------------------------------------------------------------------------------------------------- 








CONTENTS 

Chapter Description 

No. 

1. Introduction & Machine details 

2. 

3. 

Scope of Supply & Work 

Climatic condition 

4. 

5. 

Standards 

Power supply condition 

6. Technical Specifications 

7. Specification of Motors 

8. Power distribution on machine 

9. Specification of main control desk 

10. Specification of control panels. 

11. Control modes 

12. Limit switches & Junction boxes 

13. Brakes 

14. Resistance boxes 

15. Light fittings 

16. Specification of cables 

17. Identification of circuits & cables etc. 

18. Earthing 

19. Air conditioning 

20. VVVF 

21. PLC 

22. Particular requirements 

23. Tests 

24. Drawings & documents 

25. Make of electrical equipments 

26. Preferred makes 

27. List of drawings 


----------------------------------------------------------------------------------------------------------------- 








Schedules 

Schedule -1 List of commissioning spares 

Schedule -2 

Special tools, tackles & 

instruments 

Schedule -3:- 

Schedule -3 

Format for LT motor data sheet 

Schedule -4 

Schedule -5 

Schedule -6 

Schedule -7 

Schedule -8 

Standard specification for 

programmable logic controller 

Standard specification for VVVF 

converters(AC drives) 

Standard specification for LT 

inverter duty motor 

Standard specification for 

uninterrupted power supply system 

List of commissioning spares for 

two years operation & maintenance 

Drawings 

Sl. No. Drg. No. Title 

1 1522.96.001 Single line diagram 

dule -3:- 2 SK-EDB-1091 PLC configuration diagram 

3 SK-EDB-1055 Sketch of electric panel room 

4 1522.61.000 GA Drg. of coke pusher 


----------------------------------------------------------------------------------------------------------------- 




QUALIFYING CRITERIA: 





1)The tenderer should have carried out electrical work related to steel plant equipment 

including VFD & PLC in past, covering design, engineering, supply, erection, testing & 

Commissioning. The claim should be substantiated with submission of documentary 

evidence including performance certificate from the users/customers. 

2)The annual turnover of the tenderer shall be minimum 3 crores in last three consecutive financal 

years. Tenderer shall submit audited balance sheet for last three years. 

1.0 INTRODUCTION 

1.1 BACKGROUND 

1.1.1 SAIL-DSP was set up as an integrated steel plant in India. The plant is 

located at Durgapur, in Burdwan district of West Bengal & is located on 

the main Howrah- Delhi railway line. 

SAIL- DSP desires to rebuild Coke oven battery no. 2 

1.2 COKE OVEN BATTERIES 

Main parameters of the batteries are given below: 

Parameters Battery No. 2 

No. of ovens 78 (2 blocks of 39 ovens each) 

Oven Dimensions 

Height 4450 mm 

Avg. width 450 mm 

Length 13590 mm 

Useful volume 23.8 m3 


----------------------------------------------------------------------------------------------------------------- 




1.3 Oven Parameters 





a) Number of Ovens 78 

b) Oven height 4450 mm 

c) Oven width 450 mm(average) 

d) Oven length 13590 mm 

e) Oven taper 60 mm 

f) Oven volume 23.8 m3 

g) Oven pitch 1100 mm 

h) Oven sole level +84296 (Cold)/ +84326 (Hot) 

i) Pushing series 5-2 

j) No. of charging holes 4 

k) No. of gas collecting mains 2 

l) Quenching system Wet quenching 

m) 

n) 

Coking Time 

) 

Track level 

18 Hours 

+77590 

1.3.1 Pertinent data in respect of the machine tracks (machine tracks are 

covered in Battery proper) are as follows:- 

Machine 

Tracks 

Pusher 

Car 

Rail Gaug 

e 

CR-100 

(178.5 lb/yd) 

(mm) 

10058 

(C/C) 

Wheel 

Load 

(max) 

19t 

(max.) 

Maximum 

length 

(mm) 

Power 

Feed 

15700 Trolley 

Wire 

1.4 Travel Mechanism 

Travel mechanism shall be designed to prevent derailing of the machine. 

Provision for easy re-railing shall be provided. 

Spring grid couplings shall be used between motor and reducer of LT 

mechanisms. 


----------------------------------------------------------------------------------------------------------------- 




Car 





Emergency stop provision shall be provided near LT drives for Pusher 

Generally the LT speed shall be kept on lower side subject to fulfilment of 

average pushing rate of 96 ovens per day considering 22 hr/day pushing 

time and other technical/operational requirement. 

Fail safe spring engaged DC electromagnetic brake shall be provided as 

parking brake. 

1.5 Track details: 

a) Track rail size CR 100 (178.5 lb/yd) 

b) Weight of rail per meter 88.96 kg 

c) 

d) 

Track center to 

center distance 

Gradient 

10058 mm 

Level 

e) Curvature Nil 

1.6 Main Features of Machine: 

Type Single spot with hydraulic drives 

Arrangement of leveller with 

respect to pusher ram. 

Control of drives By PLC 

Speed control of LT drives 

Speed control of ram drive -do- 

Speed control of leveller drive -do- 

Right of pusher ram ( looking at the 

battery from pusher side) 

By means of A.C. squirrel cage motors 

with VVVF control and frequency 

converters. 

Centralised Lubrication Motorised multi line/ two-line system 

System 

Power Collectors As existing 

Page 10 of 100 

----------------------------------------------------------------------------------------------------------------- 




Spotting System 





Refer electrics write – up (Annexure-II) 

Emergency drive for Pusher Withdrawal by air motor & an electrical 

Ram 

winch with manual operation facility 

Pusher Ram Straight with rack & pinion 

Cleaning of rack teeth By compressed air 

Measurement of pushing Force By Ammeter, to be displayed digitally in 

the Operator‟s Cabin 

Degraphitising By ram head mounted cutters and 

compressed air 

Protection covers for Pusher To be provided. 

Ram 

Leveller emergency drive Electric winch along with manual 

operation facility 

Leveller spillage coal bunker To be provided. Capacity to suit at least 

14 (fourteen) oven cycles 

Leveller door opener Upward opening, mechanized by 

means of LDT mounted hydraulic 

cylinder 

Leveller muff With air curtain. Muff sleeve movement 

by hydraulic cylinder 

Safety barriers To prevent access through service 

bench during pushing. 

Door Extractor With Vertical compensation 

Door turn by Hydraulic Cylinder 

Frame Cleaner Spring mounted scrapers to clean 

sealing surfaces, internal side surfaces, 

oven sole & side surfaces, mounted on 

carriage with vibrator. 

Oven sole cleaning with compressed 

air. Vertical & Horizontal movements by 

means of Hydraulic cylinders 

Door Cleaner Spring mounted cleaning tools 


----------------------------------------------------------------------------------------------------------------- 








mounted on travelling carriage with 

vibrator. Hydraulic cylinder operated 

Operator‟s Cabin Double – walled with insulation. 

Air conditioned. Roof & side sheeting – 

SS plates 

Hydraulic cabin Double – walled with insulation. 

Air conditioned. Roof & side sheeting – 

SS plates 

Electronic panel Cabin: Double – walled with insulation. 

Air conditioned. Roof & side sheeting– 

SS Plates 

Electric Panel Cabin Ventilated with pressurised filtered air 

UPS 

Interlocking with other Oven 

Machines 

See Electrics (Annexure-II) 

See Electrics (Annexure-II) 

Hydraulic System : 

Fluid Water Glycol 

Main Pumps Pressure compensated axial piston 

pumps ( 1 working, 1 standby) 

Cooling filtration System Separate with air – oil cooler and 

duplex filter 

Tank Stainless Steel oil tank, t = 6 mm 

Piping Stainless Steel pipelines & fittings 

Emergency Drive By accumulator and hand pump 

Pneumatic System - 2 Compressors on each pusher car. 

- Air Receiver of 10 m 3 capacity. 

- for Degraphitising of oven roof 

and stand pipe ports 

- Blowing soot from the ram rack 

surface 

- For emergency withdrawal 

mechanisms 


----------------------------------------------------------------------------------------------------------------- 








Air conditioners Split type (LINTERN,USA make) 

Laser gun To be provided for spotting 

Heavy duty Industrial Vacuum For Cleaning Cabins & equipments 

Cleaner 

Water jet with SS tank To Quench spilt coke & door blazing 

Pushing Load transfer To civil foundation of Pusher car track 


----------------------------------------------------------------------------------------------------------------- 




1.7 Desired Speeds: 

1.8 Other Parameter: 





a) Long Travel 60 m/min. 

b) Pusher 25 m/min. 

c) 

d) 

Leveller: 

Door screw turning 

45 m/min. 

Through cyclo gear box 

e) 

f) 

Other mechanisms: 

No. of pushes 

Designed speed of drives 

shall be commensurate 

with the overall machine 

cycle time 

96/day 

g) 

h) 

Cycle time 

Speed of hydraulically 

operated devices 

Less than 600 seconds 

6 m/min 

1.8.1 Height of end buffers above rail 755mm 

level 

1.8.2 Clearance with the battery As per machinery diagram 

1.8.3 Buffer to buffer distance 15700 mm 

1.8.4 Distance from oven face (Hot) to 

first rail 

3862 mm 

1.8.5 Clearance 32004 mm between CL of 

battery and extreme point 

of machine outer edge 

along the length of oven. 

1.8.6 Oven sole level (Hot) +84323 mm 

1.8.7 Pusher ram length 22320 mm 

1.8.8 Pusher ram travel 19750 mm 

1.8.9 Max. Pushing force 28t 

1.8.10 Leveller Bar length 21600 mm 


----------------------------------------------------------------------------------------------------------------- 








Leveller bar travel 14410 mm 

1.8.11 Wheel loads Not more than 19 tons 

(Max. permissible load due 

to limitations of the 

existing track) 

1.8.12 Power Supply and Electrical 

Systems 

1.9 Drives: 

Power Supply 415 Volt.,3 phase ,50 Hz 

Control Voltage 230 Volt, single phase ,AC, 

50 Hz 

Lighting, air- conditioning and fans 230 Volt, single phase ,AC, 

50 Hz 

Solenoid valves 24V D.C 

Motion Drive 

- Travel Electric motor with gear box 

- Pushing Electric motor with gear box 

- Leveller Electric motor with gear box 

- Door screw turning Through Cyclo gear box 

- Door swiveling By Hydraulic cylinders 

- Door Extractor Travel Hydraulic Cylinder 

- Door Lift LDT mounted hydraulic cylinder 

- Door Latch bars Hydraulic Cylinder 

- Vertical 

Compensation device 

for door extraction 

LDT mounted hydraulic cylinder 


----------------------------------------------------------------------------------------------------------------- 








- Frame Cleaner Travel 

- Frame Cleaner 

swiveling 

Hydraulic Cylinder 

By Hydraulic cylinders 

- Frame Cleaning Hydraulic Cylinder 

- Frame cleaner spring 

pressing 


- Frame cleaner fixing Hydraulic Cylinder 

- Frame cleaner 

blocking 

- Door Cleaner Carriage 

- Door top horizontal 

cleaning 

- Door bottom 

horizontal cleaning 





- Door vertical cleaning Hydraulic Cylinder 

- Door Cleaning travel 

- Leveller Door opening 

- Leveller Hood muff 

- Leveller Sluice travel 


LDT mounted hydraulic cylinder 




----------------------------------------------------------------------------------------------------------------- 




- Spillage Coke 

deflector 






- Coal spillage chute Hydraulic Cylinder 

- Spillage Coal Bin 

Discharge Gate 

1.10 Functional Description 

1.10.1 List of Functions: 

1.10.2 Spotting 


These are the functions required for servicing the ovens: 

- Machine travelling 

- Door servicing including slewing 

- Interlocking the machine during the pushing procedure 

- Pushing of the coke 

- Removal of roof carbon in the gas collecting space in the oven 

chamber. 

- Removal of carbon from the standpipe port in the oven 

chamber. 

- Opening and closing the leveller door. 

- Sealing the leveller hole during levelling by leveller muff & air 

curtain. 

- Levelling the coal charge. 

- Cleaning the oven door. 

- Cleaning the door frame. 

- Collection and removal of leveller coal. 

- Removal of door cleaning residue into a collecting device. 

- Guiding of spilt coke to the spillage conveyor. 

- Collection & disposal of debris collected during ram withdrawal 

& door cleaning 

- Generation of compressed air. 

- Generation of hydraulic pressure. 

- Air-conditioning of operator‟s cabin, electronic panel cabin & 

hydraulic cabin. 

- Emergency withdrawal of the pusher and leveller beams. 

- Spotting with the aid of laser spotting. 


----------------------------------------------------------------------------------------------------------------- 








The Coke Pusher machine shall be spotted into working position at an 

accuracy of ± 5 mm or even better. 

For further details, refer Electrical write-up Annexure-II 

1.10.3 Door Extracting: 

The door servicing equipment is slewed into working position and 

moved in front of the oven. The hydraulically operated lifting device 

moves the extraction arms under the extraction beams of the door. 

The door latches are disengaged the unscrewing them with the help of 

Cyclo gear box. 

Hydraulic cylinder of the Vertical Compensation Device is blocked in 

tilted position. This is to ensure that the deviation from the vertical, 

which is caused by the chamber frame, shall be maintained while 

latching the door back after its pushing operation is over so that 

damage to the chamber frame and door sealing is avoided. 

The door is then lifted by 30 mm approx. with the help of LDT 

mounted hydraulic cylinder, run back, lifted into the final position (to 

obtain the same level for the cleaning equipment) and slewed into the 

door cleaning equipment. 

Re-installation of the door after completion of the pushing procedure 

and cleaning of the chamber frame is carried out in reverse sequence. 

1.10.4 Pushing and Carbon Removal: 

Prior to the beginning of pushing procedure, the machine sub 

structure shall be securely held in position with the help of a wedge 

type mechanism which can be lowered & lifted in order to provide a 

firm rest on the vertical impact surface on the machine track 

foundation. The traveling drives are then interlocked. 

Pusher and leveller shall be driven by electric motors which, in 

connection with mill duty electromagnetic DC brakes and /or 

proximity switches, ensure precise attainment of final or intermediate 

positions. 


----------------------------------------------------------------------------------------------------------------- 




1.10.5 Levelling: 





For the removal of carbon from the gas collecting space, a carbon 

scraper on the pusher head and additional nozzles made of stainless 

steel charged with compressed air shall be provided. 

An additional stainless steel nozzle supplied with compressed air 

cleans the pusher side standpipe port in the Oven Chamber. 

The equipment for leveling and for opening and closing the leveller 

doors are located 5 oven pitches away from the center line of the 

pusher beam. 

The leveller doors shall be opened or closed from the driver‟s cabin. 

Thus, it is possible to open the leveller door of oven N-5, level oven 

and close the leveller door again of oven N-5 when the pusher 

machine is in the proper position for pushing oven N. 

The spilled coal during leveling shall be collected in a bunker which 

shall be so designed that the coal from 14 (fourteen) oven cycles 

(working cycles) can be accommodated in it. Bunker inner surfaces 

shall be provided with stainless steel liners. 

The leveller coal is emptied from the collecting bunker into the 

existing spillage coal bunker of skip hoist at the coal tower. 

1.10.6 Door and frame Cleaning: 

During the pushing procedure, the door cleaning machine is moved to 

the slewed coke oven door and cleaning is done by horizontal and 

vertical tools moving to and fro, on the surfaces which are important 

for satisfactory sealing of the coke oven doors. All cleaning 

procedures are affected by resiliently compressing scraping tools. 

These are fixed at such intervals that the cleaning strokes overlap 

each other. 

After completing the pushing procedure, the door frame cleaning 

machine, by slewing and moving it in front of the chamber frame, 

cleans the front surface of the door frame using tools moving to and 

fro, which is important for satisfactory sealing of the coke oven doors. 

Internal side surface are cleaned by separate set of cleaning tools. 


----------------------------------------------------------------------------------------------------------------- 








Additionally, with a special provision, the oven sole in the area of the 

door plug and the lateral wall sections up to a height of 0.5 m approx. 

are likewise cleaned. This is carried out by resiliently compressing 

scraping tools, the distances of which ensure safe overlapping of the 

intended cleaning strokes. The cleaning of stubborn deposits is 

assisted by vibrator & oven sole is cleaned by compressed air 

supplied through nozzles suitably located on the door frame cleaner. 

Thereafter, the oven door is reinstalled again. 

The spilled coke after each pushing and door frame cleaning 

procedure is quenched by high pressure water jet & guided on to the 

spillage conveyor located on the service platform. 

The door cleaning spillage is caught by a chute and likewise 

transferred to the collecting bin. 

1.10.7 Emergency Drive for Pusher/ Leveller 

An emergency air motor drive connected through a reduction gear 

box and hand operated clutch arrangement to the main drive of the 

ram beam shall be provided for emergency withdrawal of the ram. 

Additionally, an electrical winch with manual operation facility shall be 

provided as a failsafe device. 

The air motor shall be able to withdraw the Pusher Ram even at an 

operating pressure of 2.5 Bar. 

For withdrawing the Leveller bar in case of emergency an electrical 

winch with manual operation facility shall be provided. 

1.10.8 Water tank with compressed air lines and outlet water lines for coke 

quenching & putting off door blazing to be provided. 

1.11 Control and Interlocks: 

The machine shall be controlled by the Operator from a position at the 

main control desk. This shall be laid out in an ergonomical manner and 

each main function shall be controlled in “automatic mode” by one desk 

switch e.g. “Remove Door” or “Replace Door”. The individual motions of 

each main function shall be controlled by individual switches when in 

“manual mode”, this feature is being provided for maintenance purpose. 

Interlocks 


----------------------------------------------------------------------------------------------------------------- 








Travel Drive Operation by Frame Cleaner, Retracted 

Left or Right Control handle 

with dead mean 

feature 

Door Extractor 

Remove Door 

Replace Door 

Automatic from 

desk switch 

Pusher Ram Push Operation 

by control handle 

on desk 

Door Extractor, Retracted 

Leveller Door Opener, 

Retracted 

Pusher Ram, Retracted 

Leveller Retracted 

Pusher Beam, Retracted 

Door frame Cleaner, 

Retracted 

Door Cleaner, Retracted 

Travel Stopped 

Door frame Cleaner, 

Retracted 

Arm, retracted 

Door Hooks, Engaged 

Door, Lifted 

Cross Battery, Signalled 

Interlock 

NOTE : Beam shall return automatically from end of stroke 

Door Cleaner Automatic from 

switch on control 

desk 

“Clean” Desk or bench 

control (by 

Door frame 

Cleaner 

selection) 

Automatic from 

switch on control 

desk 

Door Extractor Retracted 

Door Extractor, Hooks 

Raised 

Pusher Beam, Retracted 

Door Extractor, Retracted 

“Clean” Control desk Door Hooks Raised 

Long Travel Stopped 

Leveller Door Automatic from Long Travel Stopped 

Opener switch on control 

desk 

Open/Close Automatic from Long Travel Stopped 

Levelling switch on control 

desk (number of 

strokes variable) 

Coal Spillage Hydraulic valve Ramp on bench operates 

control by bench- permissive valve to dump 

man 

coal to elevator boot at 


----------------------------------------------------------------------------------------------------------------- 








coal bin. 

Additional interlocks, if required shall be incorporated during detail 

engineering. 

1.12 Operator Cabin: 

The Operator‟s cabin shall consist of a steel framed cabin with bay 

type front window in toughened glass set in rubber strip. The control 

console shall be situated at the front of the cabin where there shall be 

good visibility of all the motions of the machine. The cabins shall be 

double-walled with thermal insulation and shall be air-conditioned. 

Outer walls & roof of operator‟s cabin shall be of stainless steel. All 

fixtures, fasteners & fittings on the cabin shall be of Stainless steel. 

Ambient temperature of machine operation shall be 60°C. Inside cabin 

the temperature shall be maintained at 24± 2˚C. 

The cabin shall have double door entrance, with heavy duty door 

fixtures. The cabin shall be provided with cabin fans at suitable 

locations. 

1.13 Electronic & Electric Cabin: 

Immediately behind the operator‟s cabin shall be a wall with access 

door leading on to the adjacent but separate cabin, to house the 

electronic control equipment. The electronic panels shall be housed in 

this cabin. This cabin shall be double-walled with thermal insulation 

and air-conditioned. Outer walls & roof of Electronic cabin shall be of 

stainless steel. All fixtures, fasteners & fittings on the cabin shall be of 

Stainless steel. Inside cabin the temperature shall be maintained at 

24± 2˚C. 

The electric cabin shall be pressurized and ventilated by filtered air 

from fan filter units to prevent ingress of dust/ outside air. The cabin 

shall be provided with double door entrance. Outer walls & roof of the 

electrical cabin shall be of stainless steel. All fixtures, fasteners & 

fittings on the cabin shall be of Stainless steel. Ambient temperature 

of machine operation shall be 60°C. 

1.14 Hydraulic Cabin: 


----------------------------------------------------------------------------------------------------------------- 








A separate cabin shall be built on the lower platform level of the 

machine to house the hydraulic equipment. The cabin shall be doublewalled 

with thermal insulation and shall have double door entrance. 

The cabin shall be air- conditioned. Outer walls & roof of hydraulic 

cabin shall be of stainless steel. All fixtures, fasteners & fittings on the 

cabin shall be of Stainless steel. Inside cabin the temperature shall be 

maintained at 24± 2˚C.Ambient temperature of machine operation shall 

be 60°C. 

Layout of the hydraulic equipments within the hydraulic cabin shall 

ensure adequate space for maintenance. The tank, main pumps & 

valve stand shall have separate location within the Hydraulic cabin. 

ELECTRICS 

2.0 Scope of supply & work: 

i) Work order no. 0093-002-110 

ii) Item code 5531711158 

-3:iii) 

Qty. 

1 set. for each coke pusher 

-3:iv) 

Total Qty. 

2 sets. 

2.1 (a) This tender specification calls for turnkey execution of the job 

covering 

the design, engineering, manufacture, supply FOR HMBP stores at 

Ranchi, receipt of material from purchaser‟s store at DSP, 

transportation from purchaser‟s store at DSP to coke oven site, 

handling, storage and re-conservation at DSP site, erection, testing, 

commissioning of electrics with standard accessories and attachment 

as covered in this specification. Demonstration of the proper 

functioning of the electrical system during performance guarantee test 

of the equipment in a coordinated and integrated manner as per the 

relevant clauses of this specification. 

(b) The technical specification shall be read in conjunction with General 


----------------------------------------------------------------------------------------------------------------- 








Technical Specification (GTS).The provisions given in these 

documents shall be complimentary to one another. However, in case of 

any conflict between the provisions of these documents with respect 

to technical matter, the provisions in the technical specification shall 

prevail. 

(c) The scope of supply and work covers turnkey execution of complete 

electrics for coke pusher machine. The BOQ indicated in this 

specification covers all major electrical components. Any component 

not covered in this BOQ, but considered essential for proper 

functioning of the electrical system within the parameter of this 

specification shall be deemed to be included in the scope of work of 

this tender. 

2.2 Reference drawings & documents(Intrested tenderer may request for soft copy of 

the drawings/documents. 

1) Single line diagram- 1522.96.001 

2) PLC configuration diagram- SK-EDB-1091 

3) Sketch for electrical panel room-SK-EDB-1055 

4) GA Drg. of coke pusher-1522.61.000 

5) GCC- Relevant clauses applicable to tenderer. 

2.3 The scope of work of Tenderer shall include but not be limited to the following: 

� Current collectors. 

� Isolators and protective switch gear 

� AC Motors, Inverter duty motors fed from VVVF Drives, D.C. 

Electromagnetic brakes. 


----------------------------------------------------------------------------------------------------------------- 








� Rotary type, lever type, non-contact type limit switches and 

safety switches. 

� Various types of sensors. 

� Resistances. 

� Motor control panels. 

� Control desks for housing HMI system and other equipment as 

per specifications and inductive master controller for VFD 

drives etc. 

� Programmable logic controller complete with required inputs / 

outputs for Pusher car. Touch screen monitors (15” or higher ) 

with inbuilt RAM, key board, printers and other required 

peripherals. Cold standby system with redundant CPU, Power 

supply and communication porcessor shall be provided in each 

machine PLC. CPU shall be of latest version type. 

� Variable voltage & variable frequency AC drives, tacho- 

generators/pulse encoders. 

� Uninterrupted power supply system. 

� Lighting transformer, lighting distribution panels, lighting 

fixtures with lamps, socket outlets.. 

� Power, control, heat resistant, communication & special cables. 

� Earthing equipment and materials including electronic earthing. 

� Submission of Drawings and documents including GA, SLD, 

BOM, Control scheme, QAP and all layout drawings, technical 

catalogues/ Data sheets. 

� Arranging construction power supply and temporary lighting 

during storage, erection, testing and commissioning. 

� Adequate number of shock treatment charts, danger and 

caution notice boards, first aid boxes, keys with key boxes, 

rubber mats. 


----------------------------------------------------------------------------------------------------------------- 








� Electrical room / operator room furniture. 

� Erection/installation/fixing materials like GI pipes, supporting 

structures for mounting of equipment, cable trays and 

their supporting structures, cable and pipe clamps, ferrules, 

asbestos wire rope etc. 

� Commissioning spares & Consumables as required till the plant 

is commissioned and handed over to Purchaser. Minimum 

commissioning spares shall be supplied along with main 

equipment.(as per schedule- 1) 

� Two years spares for normal operation & maintenance of 

equipment.(as per schedule-8) 

� Tools & tackles required for maintenance of equipment. (as per 

schedule- 2). 

� Radio positioning & interlocking system for Pusher Cars shall be 

provided under Coke Heating & Control System (CHCS) Package. 

Following shall be provided by Tenderer (Machine package supplier) 

to ensure proper implementation of Radio positioning & interlocking 

system and CHCS System and included in scope of supply of 

Tenderer. 

a. Porfibus connectivity to CHCS system PLC (Siemens 

make CPU-315-2DP). One number panel enclosure 

(800mm width) for mounting CHCS PLC and other 

accessories shall be provided inside the electric cabin. 

b. Machine operated related data generation essentially 

required for interlocking 

c. Joint implementation of communication software between 

m/c PLC and RTUs under CHCS system Package. 

d. UPS Power supply (1000VA) for CHCS PLC and other 

accessories. 

e. Aux. power supply as required. 

f. VVVF Drive for Machine travel mechanism shall be 

provided with Torque & Vector control so that Machine 

should operate at 3% creep speed. 

g. HMI Screen implementation (5 pages min.) 

h. Number of Tags as required.( 200 minimum). 


----------------------------------------------------------------------------------------------------------------- 








i. Tenderer shall work in close coordination with other 

automation suppliers and CHCS Package supplier for 

establishment of proper communication between oven 

machines, integrated operation of Oven machine radio 

positioning & interlocking up to 6 months from the date of 

commissioning for maximum three visits of one week 

each. 

j. Space for cabling, cable trays, GI pipes etc by CHCS 

supplier. 

� Data as required for CHCS system shall be provided by 

Tenderer and the same shall be finalized during detail 

engineering as per system requirement. 

� Tenderer scope of supply includes all the components, 

materials and accessories required to render the equipment 

and system offered complete and fully operative in all 

respects even though every individual item necessary might 

not have been detailed out explicitly in this specification. 

� Items not specifically mentioned but required for successful 

completion of the work are included in the scope of work of the 

Tenderer. 

� The drawings shall be furnished by the tenderer during detail 

engineering as listed in clause-27 of this specification. Approval 

of these drawings from DSP/ MECON shall be responsibility of the 

tenderer 


----------------------------------------------------------------------------------------------------------------- 








2.4 The scope of supply for each coke pusher shall cover, but not be 

limited to the following items :- 

Sl. 


BILL OF QUANTITY (BOQ), for each coke pusher 

Description Qty. 

1 Spring loaded current collector, 500A 8 Nos. 

2 Gravity type current collector, 500A (for earthing through rail) 2 Nos. 

3 Isolator Panel, 630A 1 No. 

4 PDB (for details refer SLD) 1 Set 

5 MCC (for details refer SLD) 1 Set 

6 Control supply transformer, 10 KVA 2 Nos. 

7 UPS system, 5 KVA, 30 min. Back-up time. 

The UPS shall confirm to the specification as indicated in 

schedule-7. 

1 Set 

8 VFD for Travel motors(Heavy duty continuous current rating 

at 50 0C should be minimum-202A). 

The VFD shall confirm to the specification as indicated in 

2 Sets. 

9 schedule-5 DC Power pack, input 240V AC, output 24VDC,rated-50A 1 Sets 

10 continuous. 

DBR for Travel VFD (Continuous rating minimum 12 Kw) 2 Sets. 

11 DC Brake and BRP for Travel motors (4 X Ø300 mm Brake + 4 

nos. BRP, for each brake separate rectifier panel shall be 

provided) 

1 Set 

12 Incremental Pulse encoder for Travel motors 2 Nos. 

13 30 KW Travel motors, Frame – 225 M, 6 Pole. 

The Motor shall confirm to the specification as indicated in 

schedule-6 

4 Nos. 

14 VFD for Pusher RAM motors(Heavy duty continuous current 

rating at 500C should be minimum- 358 A) 


schedule-5 

1 No. 

15 DBR for Pusher RAM VFD(Continuous rating minimum 22 Kw) 1 No. 


----------------------------------------------------------------------------------------------------------------- 








16 DC Brake and BRP for Pusher motor (1 X Ø500 mm + 1 no. BRP) 1 Set 

17 Incremental Pulse encoder for Pusher RAM motor 1 No. 

18 110 KW Pusher RAM motor, Frame – 315 L, 8 Pole 


schedule-6 


19 VFD for Leveller RAM motor (Heavy duty continuous current 

rating at 500C should be minimum-103A) 


schedule-5 


20 DBR for Leveller RAM Drive(Continuous rating minimum 6 

Kw) 


21 DC Brake & BRP for Leveller RAM motor (1 X Ø300 mm + 1 no. 

BRP) 


22 Incremental Pulse encoder for Leveller RAM motor 1 No. 

23 30 KW Leveller RAM motor, Frame – 250 M, 8 Pole 


schedule-6 


24 2.2 KW screw turning motor, Frame – 112 M, 6 Pole 2 Nos. 

25 Resistance boxes for Door screw motor (8 Ω / ph, 29A 

continuous) 

2 Sets 

26 Lighting supply transformer, 10 KVA 1 No. 

27 Red warning lamp, ambulance type 2 Nos. 

28 Laser Gun for spotting the machine 1 No. 

29 Machine illumination fittings with lamp 1 Set 

30 Absolute encoder for Pusher RAM Drive 1 No. 

31 Absolute encoder for Leveller RAM Drive 1 No. 

32 Control Desk (all the three master controllers in the control 

desk shall be suitable for 4-20mA analog signal, equivalent to 

GUSSMAN make, type no. – V81LB1T) 


33 Local control Panels (13 nos. approx.)in SS enclosure 1 Set 

34 Junction boxes in SS enclosure 1 Set 


----------------------------------------------------------------------------------------------------------------- 








35 Limit switches 

a)Roller lever,heavy duty type limit switches(4 nos) 

b)Inductive type proximity limit switches with temperature 

protection housing.(28 nos), (equivalent to TURCK make, type 

no. – Ni-35-CP40-AN6X2 with protective housing-SG40/2) 

c) Magnetic type proximity limit switches with temperature 

protection housing (8 nos). (equivalent to TIEFENBACH make, 

type no. – WK209/2) 

1 Set 

36 PLC system, cold standby system with redundant CPU, power 

supply and communication processor. 

The PLC shall confirm to the specification as indicated in 

schedule-4 

Ambient temperature - 60°C. 

Supply voltage – 24VDC. 

RAM memory- 1MByte (minimum) with battery backup. 

Non volatile memory backup. 

I/O handling capabilities – 

Discrete I/O - 10000 (minimum) 

Analog I/O - 4000 (minimum) 

For other details refer PLC configuration diagram 

1 Set 

37 Foot switch for electric bell 1 No. 

38 Light fitting(Refer SLD) 1 Set 

39 HMI, 15” touch screen, minimum 3000 tags, 200 screen 1 No. 

40 Printer – A4 size Laser printer. 1 No. 

41 List of Softwares 

1. PLC programming software. 

2. HMI configuration software. 

3. Drive parameterisation software. 

1 Set 

42 Power cable, control cable (flexible copper cables) and all 

special cables for PLC, pulse encoder etc. 

1 Lot 

43 Cable accessories 1 Lot 

44 Erection accessories inclosing mounting channels, fasteners 

etc. 

1 Lot 


----------------------------------------------------------------------------------------------------------------- 








45 Asbestos rope for braiding on the cables exposed to 

heat/radiation. 

1 Lot 

46 Commissioning spare (as per schedule – 1) 1 Lot 

47 Tools, tackles and instruments (as per schedule – 2) 

The minimum configuration of the Laptop shall be as given 

below- 

Core i7-2620M(2.5 GHz/1333/3 MB/35W) or higher, 8 GB RAM, 500GB 

HDD or higher, DVD-RW, 14.0" LED Back-Lit AntiGlare HD Display, HD 

Webcam, Dedicated Graphics with 1 GB GDDR5 Memory, Wireless LAN, 

Bluetooth, , USB 3.0, 6-in-1 Media Reader, 6 Cell Battery, MS Windows 7 Pro 

64 Bit . 

1 SET 

48 Documents – 

1 SET 

The laptop shall have following software loaded. 

1. Application software (PLC & HMI) 

2. Drive parameter list. 

3. Operation manual (Drive + PLC +HMI) 

4. PLC programming manual 

5. HMI programming manual 

CD 

49 2 years operational spare (only list to be furnished) 1 Lot 

List of Proximity Switches & Limit Switches mounted on various mechanism:. 

1. Proximity Switches (magnetic type) 

Long Travel Mechanism - 2 nos. 

Pushing Mechanism - 2 nos. 

Levelling Mechanism - 2 nos. 

Spare switches - 2 nos. 


----------------------------------------------------------------------------------------------------------------- 




2. Proximity switches (non-magnetic type) 

Pushing Mechanism 

Emergency Drive - 2 nos. 

Levelling Mechanism 

Emergency Drive - 1 no. 





Leveller Door Latch engaging - 2 nos. 

Smoke Sleeve Travel - 2 nos. 

Transfer Chute Travel - 2 nos. 

Spillage Coal Bunker Gate - 2 nos. 

Door Extractor 

Door Lifting & Lowering - 1 no. 

Door Latching & Unlatching - 2 nos. 

Door Cleaner 

Travel - 2 nos. 

Head Lifting & Lowering - 2 nos. 

Frame Cleaner Head Lifting & Lowering - 2 nos. 

Safety Barriers - 4 nos. 


3. Roller Lever Operated Limit Switches 

Pushing Emergency Winch Drive - 1 no. 


----------------------------------------------------------------------------------------------------------------- 








Levelling Emergency Winch Drive - 1 no. 


2.5 Scope of service: - 

2.5.1 Erection,Testing,Commissioning & Performance Guarantee test : 

2.5.1.1 Erection is included in the scope of work of the tenderer. 

2.5.1.2 For supervision of electrical erection work, the tenderer shall employ 

authorised persons holding valid electrical licence for the state of 

West Bengal. 

2.5.1.3 For erection, SAIL-DSP shall provide only electric power at nearest 

available point. All other arrangement shall be made by the tenderer 

of their own at their own cost. 

2.5.1.4 The consumables and spares required till successful commissioning 

of the coke pusher shall be arranged by the tenderer. 

2.5.1.5 All tools & tackles including special tools shall be arranged by the 

tenderer. 

2.5.1.6 The tenderer shall depute specialists in various disciplines from his 

organisation for erection, testing & commissioning. Exact period/ 

duration for deputation shall be mutually discussed and finalised. 

2.5.1.7 The tenderer shall commission the complete electrical system of the 

machine. 

2.5.1.8 The tenderer shall ensure that a minimum manpower is always 

stationed at site and additional manpower, if required shall be 

deployed depending on exigency of work till commissioning. 

2.5.1.9 The coke pusher car shall be considered as commissioned on 

completion of first pushing of all the ovens provided it is completed 

within 30 days from the date of pushing of the first oven. However in 

case pushing of all the ovens is not completed within 30 days of the 

first pushing, commissioning would be deemed to be completed. The 


----------------------------------------------------------------------------------------------------------------- 








tenderer shall be responsible for proper functioning of the electrical 

system during this PG test. 

2.5.1.10 The electrical system of the machine shall be guaranteed for capacity, 

performance and reliability for a period of twelve (12) months from the date 

of reaching the rated pushing level within the period of three months from 

the commissioning of the Battery. All equipment & component parts shall be 

guaranteed by the Tenderer against defective or improper materials, poor 

workmanship and failure from normal usage for one year from date of 

commissioning. If any defect or mal-performance occurs during the 

guarantee period, the tenderer shall make all the necessary/desirable 

alterations, repairs and replacements as desired by the Purchaser/ 

Purchaser’s representative without any cost to the Purchaser. 

2.5.1.11 The performance of individual machine shall be demonstrated for the 

following parameters: 

� Continuous and trouble free operation of the machine for 15 

days maximum or as decided by the Purchaser at rated capacity 

of 96 pushings per day. During the above period, all 

mechanisms shall be made functional and shall operate in the 

proper sequence as envisaged in the design. For non-fulfillment 

of above performance attributable to the electrical system of 

the machine, 0.1 % of the total value of electrical system 

package shall be deducted for shortfall of every one oven of 

production. 

2.5.1.12 Separate experts for electrical system shall be deputed during PG test. 

2.5.2 Responsibility matrix for free issue items :- 

Sl. 

No 

. 

Equipment Equipment 

supply 

Cable 

Supply 

Installati 

on 

Commissio 

ning 

1. Air Conditioning Equipment 

a. A/c Unit HEC Tenderer HEC HEC 

b. Control 

Panel 

HEC Tenderer Tendere 

r 

Assistance 

By 

Tenderer 


----------------------------------------------------------------------------------------------------------------- 




2 

3 





Lubrication equipment 

Control 

panel 

Pushing ram winch 

Control 

panel 

4 Leveling ram winch 

Control 

panel 


r 


r 


r 

Assistance 

By 


Assistance 

By 


Assistance 

By 


5 Hydraulic system 

6 

a. Hydraulic HEC 

Unit 

b. Control Tenderer 

panel 

Pneumetic system 



HEC 

Tendere 

r 

HEC 


a. 

pneumetic 

Unit 

HEC Tenderer HEC HEC 

b. Control 

Panel 

Tenderer Tenderer Tendere 

r 


7 Vibrator HEC Tenderer HEC HEC 

8 Air blower HEC Tenderer HEC HEC 

for leveller 

9 Water pump HEC Tenderer HEC HEC 

2.6 Following documents to be furnished by the tenderer along with the offer:- 

1. Clausewise confirmation of TS. 

2. List of deviation (if any). 

3. Details of offered motor, VFD, PLC system etc. 

4. Offered PLC configuration diagram. 

5. Details of HMI, absolute encoder, proximity switches. 

6. List of offered softwares for PLC, HMI & VFD. 


----------------------------------------------------------------------------------------------------------------- 




3.0 Climatic Conditions 





3.1 The equipment offered shall be suitable for tropical and humid climate. 

However maximum temperature and 100% humidity may not occur 

simultaneously. The equipment shall also be suitable for elevations up to 

1000 meters above mean sea level. 

3.2 For the purpose of equipment selection and specially for de-rating the 

capacities of drive motors, switch gear and power cable an ambient 

temperature condition shall be taken as 60°C. However, AC drive (VFD) 

shall be selected considering 50°C and PLC shall be selected considering 

55°C ambient temperature. 

3.3 The equipment and cable on the machine shall be suitably protected 

against damage from radiant heat and shooting flames. All electrical 

equipments shall be of weather- proof and also dust and vermin proof. 

Unless specified otherwise, the enclosure class of the equipment shall be 

IP-55. Enclosure class for PLC & VFD shall be IP-42. 

4.0 Standards 

4.1 The equipment shall be selected, assembled and tested as per guide lines 

provided in the latest edition of "Indian Standard Specification" No. 

IS: 4137-1985 for class 3 & 4 duty cranes and shall be subject to any 

modification and requirement specified by the Purchaser. Electrical 

equipment shall also conform to following Inter Plant Steel Standards 

(IPSS) : 

� 1-03-003-94 : AC mill/crane duty slip ring induction motors(second 

revision). 

� 1-03-004-95 : AC crane duty squirrel cage induction motors 

(second revision). 

� 1-03-011-92 : AC cabin fans for EOT cranes (first revision). 

� 1-10-002-82 : Resistance boxes for power circuits (with 

amendment 1). 

� 1-10-005-81 : Master controller. 


----------------------------------------------------------------------------------------------------------------- 








� 1-10-006-81 : Drum/cam controller (with amendment 1). 

� 1-10-010-84 : General requirements for control panels for cranes 

(with amendment 1). 

� 1-10-011-84 : Particular requirements for control panels for AC 

cranes (with amendment1). 

4.2 The equipment shall also conform to the latest "Indian Electricity Rules and 

Regulations" in regard to safety requirements, earthing and other essential 

provisions specified there in. The equipment shall be designed and selected 

to facilitate inspection, cleaning, replacement and repair and for use where 

continuity of operation and safety are the main considerations. The 

Tenderer shall ensure that the equipments selected and provided by him 

shall have sufficient internal space for accommodating robust construction 

and adequate rating margins which experience has shown to be 

necessary in steel works operation and shall be ensured throughout 

manufacture. 

4.3 All imported equipment shall be as per IPSS/IS/IEC without diluting 

Purchaser's TS. In case of conflict between Purchaser's TS & 

IPSS/IS/IEC, Purchaser's decision shall be final. 

5.0 Power Supply Conditions 

5.1 The power from trolley lines shall be available at 415 volts, 3 phase, 4 

wire, 50Hz. The equipment selected shall be suitable for operation with 

voltage variation of +10% and -15%. The frequency variation shall be 

+4%, -6%. The combined voltage and frequency variation shall be +/- 

10%. 

5.2 The following voltage shall be used in the oven machine: 

� 415 volts, 3 phase, 50Hz AC for motors. 

� 240 volts AC +/-10%. for control circuit. 

� 240 volts, single phase 50 Hz AC for lighting, air conditioning, 

ventilation fans. 

� 240 V AC for socket outlets for hand tools. 


----------------------------------------------------------------------------------------------------------------- 








� 220 V, D.C. for electromagnetic brakes. 

� 24 V, D.C. for solenoid valves and I/Os of PLC.. 

� 240 V, AC through UPS for PLC input supply. 

5.3 The different voltages mentioned above other than 415 volts, 3 

phase, 50Hz AC shall be derived through individual separate 

transformer and transformer rectifier units- connected to 415 volts AC. 

The transformer shall have + 5% & + 10% taps on the primary side. One 

working and one standby transformer shall be provided for 240 volts AC 

control circuits. 

5.4 The short circuit level of the system shall be considered as 50 kA for 1 

sec. 

5.5 The maximum voltage drop during starting of motor shall be limited 

to 15 % at the motor terminals without effecting the performance of motors. 

The following shall also be noted: 

� The voltage available at the motor terminals during starting 

shall be sufficient to ensure positive starting and 

acceleration of the motor under fully loaded condition without 

any damage to the motor. 

� The voltage drop indicated shall be calculated with starting 

current corresponding to the rated voltage of the motor. 

� For DC supply and UPS outgoing feeders, it shall be ensured 

that the voltage available at the equipment being fed by DC/UPS 

feeders shall be as per equipment design basis. 

6.0 Technical Specification 

6.1 Current Collector & Trolley Lines 

6.1.1 The trolley lines (4-0 Grooved Copper Conductor) 3 Ph, 4 wire for 

operation of Pusher car shall be supplied and erected by the purchaser. 

The location of trolley lines shall be indicated by the purchaser in 

clearance diagram of the machine so that the Tenderer can arrange for 


----------------------------------------------------------------------------------------------------------------- 








the main current collectors suiting these dimensions. Fourth trolley 

shall be provided for electronic earthing purpose. The electrical earthing 

of the complete machine shall be through rail. 

6.2 Collector Shoes 

The collectors shall be provided with spring loaded adjustable base 

along with head assembly with swiveling action current collector for all 

the three phases and earth in line with existing batteries. The collectors 

shall have adequate current carrying capacity. The design of 

collector shoes shall be such as to minimise the chance of bending at the 

hinge points due to dust or corrosion. Minimum 2 nos. current collectors 

per phase and earth shall be provided. Current collector for Pusher car 

shall be suitable for trolley line. 

6.3 Collector Shunts 

6.4 Mountings 

Current carrying shunts on all the collectors shall be designed so that 

there is no danger of contact with adjacent collectors. The shunts shall 

be easily replaceable. 

All the collectors shall be mounted on rigid steel supports and suitably 

insulated. Electrical clearance between live parts of adjacent shoes shall 

be at least 25 mm. Flexible shunts in their least favorable position shall 

not reduce this clearance. Collectors shall be designed for ease of 

maintenance and mounted suitably so that they are readily accessible 

for this purpose. Accordingly suitable working platform shall be 

provided. Further current collector to be suitably located so that spillage 

of coal & oil from the car does not fall on collector. 

7.0 Specification of Motors 

7.1 Except for Air Conditioning, Compressor and hydraulic drives, all 

motors shall be crane duty suitable for minimum 150 starts per hour, 

having duty cycle rating S-4, 40% C.D.F., unless specified otherwise. 

Motors for air Conditioning, Ventilation, Compressor and hydraulic 

drives shall be S1 Duty. Motor fed from VVVF drive shall be Inverter 

duty as per specification. 


----------------------------------------------------------------------------------------------------------------- 








All motors shall be totally enclosed, fan cooled, horizontal foot mounted with 

IP-55 protection class. The motors shall comply to the latest Indian, 

International standards and IPSS. The supplier shall be responsible 

for selecting the ratings that shall be required for the specified duty 

with type of control specified. Ambient temperature correction factors 

depending upon ambient temperature specified shall be used to de-rate 

the motor. The Tenderer shall clearly indicate the above de-rating 

factors in their design. The motor bearing shall be heavy / medium duty 

series. 

The motor shall have cylindrical shaft extension. 

7.2 All motors shall be squirrel cage motors. Inverter duty Squirrel cage 

motors with AC drive shall be provided for drives requiring speed 

control. 

7.3 The motors shall be so selected that the motor temperature rise in actual 

service, which may include severe repetitive duty, interval of slow speed 

of operation, electrical braking requirements, etc., shall not exceed the 

permissible limits. 

7.4 Horse power 

7.5 Torque 

The motor horse power shall be computed as per IS: 4137-1985. The 

frame size shall be selected according to `kW' mentioned against it in the 

relevant IPSS specification shall not be less than the designed/computed 

power. The calculations for selection of motors shall be submitted to 

consultant for approval. 

The pull out torque of the motors at rated voltage and frequency shall 

not be less than 2.75 times of nominal torque. 

7.6 Class of Insulation 

The motors shall have minimum class „F‟ insulation with temperature 

rise limited to class „B‟. Inverter duty motors shall have class H 

insulation with temperature rise limited to class F. 

7.7 Thermistor Protection 


----------------------------------------------------------------------------------------------------------------- 








The intermittent duty motors shall be provided with thermistors to take care 

of thermal over stressing. 

7.8 Travel motors on all the oven machines shall be preferably with 

synchronous speed of 1000 rpm. 

8.0 Power distribution on machines 

8.1 An on-load manual MCCB isolator with locking facility shall be provided 

immediately after current collectors on incoming line on the machines. 

Power from the isolator shall be taken to the moulded case circuit 

breaker followed by a power contactor. This circuit breaker shall be of 

crane duty type. The breaker shall be provided with under voltage, 

overload and short circuit releases. Fault level for the protective 

switch gear shall be 50KA (minimum). Power to utilities like 

illumination, fans, air conditioning etc. shall be taken after isolator. 

8.2 Each motor feeder shall be provided with MCCB, contactor, EMPR 

and auxiliary contactors as required. Each solenoid feeder shall be 

provided with DPMCB and contactor suitable for DC rating. All power 

contactors shall be suitable for AC4 duty. Rating of power contactors 

shall be 50% higher than motor power requirement. MCB shall have 

minimum 9kA short circuit capacity. 

9.0 Specification of Main control desk 

9.1 Control desk shall be completely factory wired, sheet steel (CRCA, 2 mm 

thick) enclosed, free standing, floor mounted, with suitable covers and 

doors. Enclosure class shall be IP 54. It shall be suitable for corrosive 

atmosphere. The top cover where equipment shall be mounted shall be of 

stainless steel of thickness 2mm. All the equipment shall be mounted on the 

top cover with suitable inscriptions. 

8.2 Control desk in operator's cabin shall contain: 

� Machine power 'ON' push button and indication lights. 

� Selector switches for various sequences. 


----------------------------------------------------------------------------------------------------------------- 








� Push buttons and indicator lights required for auxiliaries 

control. 

� Master controllers (inductive type / step by step type ) shall be 

provided for the following: 

� Machine travel. 

� Pusher beam, leveller bar for pusher machine. 

� Ammeters shall be provided for the following : 

� Pusher Ram Drive 

� Leveller Drive 

� Touch screen Monitor of HMI system and printer. 

� Operator station / control desk make shall be as per preferred 

make list. 

� Particular requirement :- 

- All the three master controller shall be mounted on 

separate vertical stand. 

- Master controller for Long Travel mechanism shall be on 

LHS of operator”s chair. 

- Master controllers for Pushing Ram & Levelling Ram shall 

be on RHS of operator”s chair. 

- Components for frame cleaning mechanism shall be on 

RHS facia of control desk. 

- Components for door cleaning mechanism shall be on 

LHS facia of control desk. 

- Components for door extracting mechanism shall be on 

front facia of control desk. 

10.0 Specification of Control panels 

10.1 All MCCBs, power and auxiliary contactors, EMPR, time relays etc. shall be 

mounted in sheet steel cubicles with lockable hinged doors. The door 

hinges shall be such that during repair work inside the panel, the door can 

be lifted and placed away enabling better access inside the panel. All 

ventilating openings shall have screen protection; interior of the panel 


----------------------------------------------------------------------------------------------------------------- 








should be dust and vermin proof. Control panels shall be fully weather proof. 

Enclosure class shall be IP-54. Thermal overload relays shall not be used. 

10.2 Panels shall be front wired with readily accessible terminal blocks for 

making connection to the external equipment. Panels shall be pre-wired up 

to the terminal strip. 

10.3 All the contactors, etc. shall be mounted in vertical arrangement with 

due consideration to the vibration encountered in the operation of 

machine. 

10.4 The bottom most row of equipment mounted inside the panel 

excepting terminal strip shall be at least 350 mm above the panel 

bottom cover to facilitate inspection and repair. Panel shall be 

mounted such a way that bottom of panel is at least 150mm above the 

floor. The upper most row of equipment shall be at a height of 1550 

mm (maximum) from the floor. 

10.5 The terminal strip shall be fixed on the panel boards preferably in a 

horizontal manner, leaving enough space for termination of cables. 

Power and control terminals shall be separated from each other by 

means of replaceable insulated spacers. Terminal blocks shall have 

enough clearance to avoid tracking. The minimum size of terminal 

block shall be suitable for 10 mm 2 conductor. The minimum size of 

control terminal block shall be suitable for 4 mm 2 conductor. 

10.6 All equipment on the panel board shall have permanent identification 

label in accordance with the circuit diagram and also the power 

and control terminals. 

10.7 Terminal blocks shall be robust and of such construction so as to 

preclude the possibility of cable connections getting loose due to 

vibration on the machine. Sheet steel used for fabrication of panel 

shall be CRCA having minimum thickness of 2.0 mm. Panel shall be 

mounted such that bottom of panel is at least 150 mm above the floor. 

10.8 Panels shall be suitable for operation in corrosive atmosphere. 

10.9 Each panel shall accommodate equipment for one motion only. 

However, equipment for auxiliary drives may be clubbed in one or 


----------------------------------------------------------------------------------------------------------------- 








more panels. Power and control terminals shall be segregated. 20% 

spare control terminals shall be provided in each panel. 

10.10 Fault indications shall be available on the doors. 

10.11 Panels shall be mounted on suitable shock absorber pads. 

10.12 Contactors 

10.12.1 The rating of all the contactors shall be at least 50% higher than the 

respective motor full load current at the specified duty cycle, it is supposed 

to control. The power contactors shall be of AC4 duty and the minimum 

rating shall be 30 A. 

10.13 Circuit protection switch gear 

10.13.1 Protection switch gear shall consist of the following: 

� One triple pole MCCB fitted with over load release for protection 

against sustained overload and magnetic type instantaneous 

release for protection under short circuit conditions on all the 

three phases. The breaker shall have adequate rupturing 

capacity to withstand and clear fault current of the order of 50 

kA. 

� One triple pole contactor shall be provided after MCCB. 

� A suitable arrangement shall be made in the system to facilitate 

control testing with power circuit off. This shall be done by 

providing disconnecting links in the power circuit. Arrangement 

shall be made for quick removal of links. These links shall be 

covered with a hinge type cover. 

� To indicate when power and control sources are ON, pilot 

indication lamps shall be provided insider the driver's cabin. 

10.13.2 In addition to incoming circuit breaker, the following protective equipment 

shall be provided inside the driver's cabin: 

� Double pole MCBs for isolation and protection of lighting and 

socket outlet circuits. 


----------------------------------------------------------------------------------------------------------------- 








� One double pole MCB for isolation and protection of control 

circuit. 

10.13.3 For the protection of each drive motor and the control circuit for every 

motion of the car, Microprocessor based overload relays and miniature 

circuit breakers respectively shall be provided. The overload relays shall 

have adjustable settings. The over load relays shall have inverse time 

current characteristics and shall be self resetting type. NC contacts of all the 

overload relays shall be connected in series and incorporated in trip circuit 

of incoming breakers trip off. For protection of control circuit against 

sustained overload and short circuit conditions, miniature circuit 

breakers shall be provided for control circuit and shall be housed in 

respective control panel. Breakers shall be of reputed make. 

10.14 Auxiliary switch-gear 

10.14.1 All fuses shall be HRC link type. 

10.14.2 Emergency stop push buttons (stayput type). 

Safety switches of sustained contact type shall be provided at the 

entrance to the car so that under any emergency conditions, by 

operating the switch, the incoming circuit breaker is tripped thus 

cutting off power to all the motors. A pilot lamp incorporated in 

control circuit shall glow-up when any of these switches are operated. 

Further a mush room head type, "OFF" push button should be 

provided in the operator‟s cabin so that the main incoming breaker 

can be tripped under any emergency conditions by pressing the 

operating head. Safety switches shall also be provided near LT Motors 

for Charging car and Pusher car. 

10.15 All outgoing feeders of MCC shall be as follows: 

� Motor feeders shall be provided with MCCB (suitable for motor 

protection) contactor & microprocessor based overload relay 

and required number of selector switches, control switches, 

auxiliary contactors, ammeters etc. 


----------------------------------------------------------------------------------------------------------------- 








� Power supply feeders shall be provided with MCCB, ammeter & 

voltmeter with selector switches. 

� Control supply shall be protected with the help of miniature 

circuit breakers. 

� Solenoid valves & DC magnets shall be provided with 

MCCBs/MCBs & contactors. 

11.0 Control modes 

All the drives shall be controlled from HMI at control desk located in 

the operator's cabin. Following types of sequence control shall be 

provided. 

11.1 Semi-automatic operation 

� Different process sequence shall be automatic. Progress of a 

sequence shall depend on limit switches or sensors 

corresponding to different positions. 

� A sequence shall mean all the operations being performed on a 

mechanism at one and the same time. 

� Each sequence shall be controlled from control desk by push 

button/key board. 

� A sequence shall start only when all the preconditions and 

permanent requirements including healthiness of drives and 

circuit are met. 

� It shall be possible to switchover to interlocked step-by-step 

mode during the operation of the sequence. 

11.2 Interlocked step-by-step operation 

� Each sub-sequence of the main sequence shall be controlled 

from control desk by separate push button/key board. 

� The progress of sub-sequence shall depend on the limit switch 

position or sensors. 


----------------------------------------------------------------------------------------------------------------- 








� Each movement shall be started only after ensuring the 

necessary interlocks. 

� The progress of each sub-sequence shall be displayed on 

the control desk and monitor of HMI. 

� It shall be possible to switchover to semi-automatic mode 

only after the completion of a sequence. 

� Provision of by passing interlock shall be provided incase of 

emergency. This shall be achieved by changing mode selector 

switch. 

11.3 Other features 

11.3.1 All control shall be through PLC operated by master controller / push 

buttons / key board of HMI. Further local control stations shall be provided 

at suitable locations of drives for local control from PLC. All indicating lamps 

shall be of LED type only. 

11.4 Annunciation and indications 

11.4.1 An alarm shall be available in case of any fault. An acknowledge system 

and the fault display shall also be provided in HMI. 

11.4.2 The HMI system shall indicate the movement of jack corresponding to 

a sequence. The monitor of HMI system shall depict the required 

dynamic graphics. 

11.4.3 Whenever the travel motion of the machines is operated an audible 

alarm shall be operated through the operation of foot switch in 

operator's cabin. 

11.4.4 All hooters & sirens shall be of robust industrial design. The make shall be 

approved by purchaser. 

12.0 Limit switches & Junction boxes 


----------------------------------------------------------------------------------------------------------------- 








12.1 Heavy duty, roller lever, self reset type or rotary type, limit switches shall be 

used. 

12.2 Enclosure class of all limit switches and junction boxes shall be IP-65. 

12.3 Limit switches shall be suitable for operation in corrosive atmosphere. 

12.4 Roller lever type limit switches shall be provided with 2NO+2NC 

contacts suitable for 240V, AC, 10A or 230V, DC, 2A. 

12.5 Rotary type limit switches shall be provided with minimum 3 

spare cams and contact arrangement. Contact rating shall be similar 

to roller lever type limit switches. 

12.6 Non contact type Magnetic/proximity sensors for higher temperature shall 

be 

considered for various applications as per process requirement. The 

proximity sensor shall have suitable protective housing to withstand long 

term exposure to elevated temperatures up to +170 0 C .Two nos. of LED 

should be provided with sensor for power indication and output indication. 

12.7 Enclosure material for junction boxes, Local control station and field 

devices 

13.0 Brakes 

shall be minimum 1.6mm thick stainless steel. 

All brakes shall be of DC Electromagnetic, mill duty type only. 

Standalone brake panel shall be provided for each application. 

14.0 Resistance Boxes 

14.1 All resistances shall conform to IPSS:1-10-002-82. Punched steel grid 

resistances shall be provided. Resistance material shall be non-corrodible, 

free from brittleness. Typical material shall be AISI Grade 406 or Fechral ( 

Cr 12 - 15 %, Al 3.5 - 4.5 %, rest Fe ). 

15.0 Light Fittings 


----------------------------------------------------------------------------------------------------------------- 








15.1 Lighting shall be provided in operator's cabin, panel room, platforms, 

walkways, stair cases, control desk, working area and any other area 

required for operation of machine. 

15.2 All DPMCBs for lighting shall be provided in lighting distribution board 

in operator's cabin. 

15.3 Fluorescent lamps shall be used for operator's cabin and panel room. 

Sodium vapour lamps shall be used for all other areas. 

15.4 Suitable number of power socket outlets and hand lamp socket outlets 

shall be provided. A hand lamp with a plug and sufficient length of 

cable shall be provided with each machine. 

15.5 Lighting panel shall be separately provided. Bulk-head type fittings 

with lamps 

shall be provided in platform and on the under frame of the car and 

high pressure sodium vapour lamps for flood lights shall be provided 

on the either side of the oven machines to illuminate the track and 

other areas. The light switches shall be provided inside the operator's 

cabin. Screw cap type holders and lamps shall be used for the car 

lighting. 

15.6 Minimum 2 nos. of red revolving flash lights shall be provided on the car 

on both sides. 

15.7 The lighting transformer shall have 50% reserve capacity. The lighting 

distribution board with metal clad switches incorporating MCBs shall 

be provided in the operator's cabin for the following: 

� Car lighting 

� Fans 

� Alarm Bell. 

15.8 Socket Outlet 

Minimum of two numbers socket outlets for hand lamps shall be provided at 

operator's cabin, hydraulic cabin, MCC room and electronic panel room. 

Hand lamps shall be operated at 230V volts AC supply. Industrial type metal 

clad plug and sockets shall be provided. 


----------------------------------------------------------------------------------------------------------------- 








15.9 Suitable lighting transformer shall be provided for machine lighting. 

Minimum rating of lighting transformer shall be 7.5KVA. 

16.0 Specification of Cables 

16.1 All cables for power, control, lighting etc. shall be carried out with 1.1 KV 

grade heat resistant silicone rubber insulated flexible cable of copper 

conductor suitable for 150˚C. All power cables shall be minimum 4 mm2 

(copper) and the control cables shall be minimum 1.5 mm2 (copper). The 

wiring inside the control panel shall be with PVC insulated stranded copper 

conductor. All flexible cables shall be multi-stranded copper. Single strand 

cables shall not be used any where inside the car. All cables exposed to 

direct heat radiation shall be of special insulation or shall run in formed steel 

channels provided with heat resistant material. Cables laid on open racks 

shall run in formed steel channels provided with heat resistant material. 

Cables laid on open racks shall be adequately clamped. Cables selection 

and routing on the car shall from a part of the car design. 

16.2 GI pipes and pipe fittings if used on car for running cables, shall be of 

standard design and shall be supplied with complete accessories. Each 

motor shall be wired through separate pipe. All cables remaining live in 

open position of isolation shall be installed separately. 

17.0 Identification of Circuits, Cables etc. 

18.0 Earthing 

Adequate labels of permanent nature shall be provided as support of 

switches, fuses, contactors and relays etc. to facilitate identification of circuit 

and replacement. All panels, controller etc. are to be properly marked for 

each motor. All power, control, lighting and other cables are to be tagged at 

both ends as per cable number indicated in drawing. All equipment 

terminals are also to be marked like-wise. Only metal ferrules shall be used. 

All the electrical equipments mounted on the car shall be connected to the 

car structure by means of earthing links. The car structure in turn shall be 

made electrically continuous by providing jumpers over rivets or bolts. 

Equipment laid by flexible cable shall be earthed by means of spare core 

provided in the flexible cable. Earthing shall conform to "Indian Electricity 

Rules". Earthing shall be achieved through machine mass, rail and 4th earth 


----------------------------------------------------------------------------------------------------------------- 








conductor. Equipotential circuit shall be maintained. Copper wire of 

suitable cross section shall be used for earthing. Rubber matting shall be 

provided in operator's cabin. Earthing of all electronic equipment shall be as 

per the recommendation of supplier. 

19.0 Air conditioning 

19.1 All cabins, hydraulic rooms, electrical rooms and rooms housing electronic 

equipment shall be provided with air-conditioning equipments. Temperature 

inside Operator’s cabin shall be 24±2°C, however inside the electronic & 

hydraulic cabins it shall be 35°C. Air conditioning equipment supply is not in 

the scope of the tenderer. 

20.0 Variable Voltage Variable Frequency (AC Drives) 

20.1 All drives requiring speed control shall be provided with AC drives 

depending on the type of motor selected. AC drives shall be provided for 

travel drives of oven machines, Ram beam drive and leveller drive of 

Pusher car etc. Pulse encoder shall be provided and hooked up with drives. 

20.2 AC drives shall conform to the general specifications enclosed as Annexure. 

20.3 The following AC drives shall be provided for each machine: 

� Two numbers of AC drives for travel mechanism of pusher car shall 

be provided each capable of driving all the travel drives. Normally 

both shall be operating, driving two sets of wheel drives. Pulse 

encoders shall be provided on wheels. Output of pulse encoders 

shall be hooked up to AC drives. Generally one drive with two 

motor shall be suitable for machine travel operation. 

� Separate AC drives shall be provided for pusher beam, leveller 

drive for pusher car. 

20.4 Pulse encoders shall be provided for Ram beam drive , travel drive & 

Leveller 

drive. Analog output of pusher ram VFD panel (4-20 mA) shall be 

connected to PLC to monitor the pusher beam drive output control. 

Make of pulse encoders shall be HUBNER. 

20.5 Enclosure class of AC drive panel shall be IP 42. 


----------------------------------------------------------------------------------------------------------------- 








20.6 All AC drives shall be provided with suitably rated reactors. 

20.7 Minimum rating of AC drives & reactor shall be 180 % of the full load 

RMS current of the motor/group of motors. This shall be considered as 

the continuous current for the AC drives. Over load capacity indicated 

in the TS shall be based on the 100% continuous current indicated 

above. 

20.8 AC drives shall be microprocessor based having communication 

facility with PLCs for data transfer and speed reference set point. 

20.9 Software of drives shall be developed in such a way that after over 

voltage or under voltage when the drive trips, the AC drive shall be 

automatically resetted without any manual intervention after 

normalising of the voltage. 

20.10 The AC drive system shall be independent of trolley line design 

system being provided by the purchaser and shall not effect the 

guaranteed performance of the drive system. 

20.11 AC drive shall be provided with 1:100 speed range with dynamic 

braking. 

20.12 AC drive panels shall be mounted on anti vibration pads. 

21.0 Programmable Logic Controller (PLC) 

21.1 Each oven machine shall be provided with PLC and HMI. The system shall 

be complete with CPU, I/O racks, memory, key board and monitor. HMI 

shall depict graphics of various mechanism operation and also provide 

alarm annunciation system. Stand by system with redundant CPU, power 

supply and communication processor shall be installed in the PLC panel. 

One PLC (co-ordinating PLC) shall be provided by purchaser at battery 

control room for data communication with machine PLC. 

21.2 Communication between PLC and AC drive shall be possible for smooth 

operation of the machine. PLC shall have facility to communicate with 

Purchaser’s RTU through serial communication. 


----------------------------------------------------------------------------------------------------------------- 




21.3 PLC shall perform the following task: 





� Logic interlock functions, control & supervision of drives & 

solenoid valves. 

� Automatic sequential operation of various drives/devices 

like door handling mechanism, cleaner, pusher, charger, leveller 

etc. 

� Status indication & signalling. 

� Fault monitoring & annunciation. 

� Diagnostic features based on logical rules to recognise and 

display faults. 

� Communication with battery control room through digital radio 

link. (Hardware for digital radio link is in the tenderer‟s scope of 

supply.) 

� Report generation. 

21.4 One number Laptop with programming software and drive 

parameterisation software for each machine shall be provided 

(included in tools and tackles – schedule 2) 

21.5 Tenderer shall note that at every stage of design, engineering & software 

development purchaser & consultant shall be fully associated. 

21.6 Software of the PLCs shall be developed in such a way that after voltage 

dip when all the I/Os are disabled, the same shall be automatically 

resetted without any manual intervention after revival of the voltage. 

21.7 Enclosure class of PLC panel shall be IP42. 

21.8 Tenderer shall provide suitably rated UPS for PLCs and its 

peripherals. 

21.9 PLC shall conform to the general specifications enclosed as Annexure. 

21.10 PLC panels shall be mounted on anti vibration pads. 


----------------------------------------------------------------------------------------------------------------- 








21.11 20 % spare I/O of each type shall be provided as spare. 

21.12 Input interrogation voltage of PLC shall be 24 V DC. However, mixing of 

voltages shall not be allowed. Cabling and schemes shall be 

developed accordingly. 

21.13 All outputs shall be relay outputs. Interposing relays shall be auxiliary 

contactors suitable for 240V, AC, 50 Hz, 6A. DC rating of contacts shall be 

2A. 10 % spare interposing relays shall be provided. 

22.0 Particular Requirements 

22.1 Sizing of electrical premises shall be done as per the requirements indicated 

by Purchaser/consultant. 

22.2 The Tenderer shall take all the necessary steps to get the installation 

approved by statutory Government Authorities like Electrical Inspector, 

Factory Inspector, Insurance Official etc. Necessary assistance in form of 

application and payment of Government fees shall be rendered by 

Purchaser in this regard. Modification suggested by statutory 

authorities in equipment or installation shall be carried out by 

Tenderer at no extra cost to the Purchaser. 

22.3 Tenderer shall supply current collectors to be provided on the oven 

machines as per the design of trolley line system being provided by the 

Purchaser. Details of the same shall be given to the Tenderer during 

detailed engineering. No additional claim on this account shall be 

entertained by the purchaser. 

22.4 Performance guarantee for electrical equipment shall ensure that all 

the electrical equipment in a subsystem/system shall be capable of 

performing as per the specified and approved performance parameters 

of subsystem/system. However every electrical equipment shall also be 

capable of individual performance as per design as well as name plate 

details. This shall be demonstrated by the Tenderer to the satisfaction 

of the purchaser/consultant. 


----------------------------------------------------------------------------------------------------------------- 








22.5 Make of equipment shall be as per TS. Prior approval of 

purchaser/consultant shall be taken for make of equipment not indicated 

in TS. 

22.6 Enclosure class of the equipment shall be as per TS. 

22.7 Training of purchaser's personnel for drives(20 mandays) & PLC(20 

mandays) shall be arranged at the tenderer’s desigrated premises free of 

charge. 

22.8 AC drives panels, PLCs and its peripherals, MCC, LDB, control desk 

shall be mounted on anti vibration pads. Any other equipment 

sensitive to vibrations shall also be mounted as indicated above. 

23.0 Tests 

All routine and site tests shall be carried out strictly as per Specification and 

IS/IPSS/International Standards. Type test certificates shall be furnished for 

similar equipment. In case the type test certificates are not available, the 

same shall be conducted in Purchaser's presence, if the Purchaser desires, 

at no extra cost to the Purchaser. 

24. Drawings & Documents 

24.1 Information/data/drawings to be furnished for Electrics by the Tenderer for 

approval 

24.1.1 Basic engineering 

� Single line diagrams of MCCs, PDBs, MLDBs, LDBs etc. 

� Power control and regulation schemes of AC drives. 

� Layout of electrical rooms and control rooms including 

ventilation air conditioning and handling facilities. 

� Layout of electrical equipment in electrical premises & 

operator's cabin. 


----------------------------------------------------------------------------------------------------------------- 








� Voltage drop calculations for incoming power cables & outgoing 

power cable for motor. 

� Quality Assurance plan for various equipments. 

� List of motors, limit switches & other field equipments. 

� Maximum demand calculation for each MCC, PDB, MLDB etc. 

� Motor rating & AC drive rating selection & calculation. 

� List of drawings. 

24.1.2 Detailed engineering 

� Single line diagrams with ratings for MCCs, PDBs, LDBs etc. 

� Bill of materials with technical specification. 

� General arrangement drawings with complete dimensions and 

list of inscriptions for all equipment. 

� Power and control schemes for protective panel and other 

drives with bill of materials, technical specification, type/make, 

etc. 

� Power, control & regulation scheme for AC drives and UPS. 

� Automation configuration with control philosophy write up 

indicating control, interlocking and automation 

details.Functional description of drives & interlocks. 

� List and details of hardware with specifications. 

� G.A drawings of panels. 

� Power supply scheme. 

� List of I/Os, Block Logic Diagram and BOQ of PLC 

� Hard copy of software. 


----------------------------------------------------------------------------------------------------------------- 




24.1.3 Illumination 

� Layout drawings. 





� Layout of electrical equipment on the oven machine. 

� Equipment & cable layout in electrical premises and 

control/operator rooms with sectional views. 

� Layout of cable trays/structures, GI pipe layout and cable layout 

on the machine with sectional views. 

� Battery and UPS capacity calculations. 

� Motors and field devices 

- G.A drawings. 

- Technical data sheet. 

� Cable specification. 

� Single line diagrams with ratings of power components for 

LDBs. 

� Bill of materials with technical specificationof 

equipment/component /fittings. 

� Illumination layout containing the type and rating of all 

equipment with list of the luminarie for the machines. 

24.2 Information/data/drawings to be furnished by the Tenderer for reference 

� All drawings and documents approved by MECON. 

� Terminal plan drawing for all equipment. 

� Cable schedule. 

� Interconnection diagrams. 


----------------------------------------------------------------------------------------------------------------- 








� Layout of earthing system for the equipment. 

� Technical particulars, catalogues, literature etc. 

� Consolidated bill of materials for erection & installation 

items like GI pipes & fittings, cable trays, earthing materials etc. 

� Spare parts list & drawings. 

� Instructions for storage/erection, testing & 

commissioning. 

� Operation & maintenance manuals. 

� Final test certificates from suppliers and site tests. 

� As built drawings. 

24.3 Information/data/drawings to be furnished by the Tenderer as final 

technical documentation. 

� All drawings, documentation and calculations indicated above. 

� List of drawings & drawing numbering system explanation. 

� Motors & field devices : 

� Speed-torque, current vs. time, thermal withstand 

characteristics for motors. 

� List of interfaces between the Tenderer‟s equipment and 

Purchaser's equipment. 

� Internal wiring diagrams of equipment. 

� Illumination 

� Schedule of equipment with their location 

� Connected load and maximum demand for machines. 


----------------------------------------------------------------------------------------------------------------- 




� Cable schedule. 

� All approved drawings. 





� Internal layout and wiring diagrams of all panels. 

� All as built drawings. 

� Technical specification/ data sheets of equipment and light 

fittings. 

24.4 Drawings/documents for inspection of electrical equipment 

� Type test certificate for identical equipment. 

� Sub-supplier's or vendor's catalogues, technical literature. 

� Test reports and internal inspection report by Tenderer. 

� Test certificates of components/equipment. 

� Technical specification & data sheets of equipment. 

� All "Approved" drawings. 

25.0 Make of Electrical Equipment 

1. Due consideration shall be given to inventory control, interchangeability, 

trouble shooting etc. in design and selection of 

equipment and controls. 

2. Efforts shall be made to offer maximum indigenous electrical 

equipment. 

3. Make of all indigenous electrical equipment shall be selected 

out of Purchaser's "Preferred Makes of Equipment and 

supplies". 

4. Make of all imported electrical equipment shall be selected in 

consultation with the Purchaser. 


----------------------------------------------------------------------------------------------------------------- 








5. In case make for some of the equipment/components are not 

indicated in the Purchaser's "Preferred Makes of Equipment and 

supplies" then the same shall be finalised in consultation with 

Purchaser/Consultant. 

6. In case the electrical equipments are imported, these shall be 

tropicalised. It shall be ensured that the components used are 

also available from Indian sources. Sufficient spares shall be 

supplied for imported equipment/ components. 

7. Tenderer shall ensure against the OBSOLESCENCE of 

equipment under their scope of supply for a minimum period 

of 10 years. The Tenderer shall also guarantee that 

discontinuity of production of any item offered as part of the 

system shall not affect the maintainability of the system. The 

Tenderer shall submit an undertaking to this effect along with 

the offer. 


----------------------------------------------------------------------------------------------------------------- 




26.0 Preferred Makes 





a) Make of motor : ABB/KIRLOSKAR/CGL/BB/ALSTOM/ 

SIEMENS/ BALDOR 

b) Make of panels : RITTAL/BCH WITH APPROVED 

COMPONENTS 

c) Brake (DCEM) : BCH 

d) MCCB : 

GEPOWER/SCHNEIDER/ABB/SIE 

MENS. 

e) Contactor : ABB/SCHNEIDER/L&T/ 

SIEMENS/GEPOWER/BCH. 

f) Thermal O/L Relay : SIEMENS/BCH/SCHNEIDER/L&T/C&S/ 

GEPOWER /ABB 

g) EMPR : LG/SPECHER&SCHUH/BCH/SIEMENS 

h) Selector switch/ : SIEMENS/BCH/GEP/KAYCEE/ABB 

push button 

indicating lamp 

i) Limit switches : EPCC (KAKKU) / AG MECHANICAL 

j) MCB : MDS/STANDARD/SCHNIDER/ 

ABB/SIEMENS 

k) Meters : MECO/IMP 

l) Lighting : PHILIPS/ CG/BAJAJ 

fixtures 

m) HRC Fuses : GEPC/SIEMENS/L&T 

n) Master controller : SCHNEIDER / SIEMENS / 

STROMKRAFT 


----------------------------------------------------------------------------------------------------------------- 








o) PLC : ROCK 

WELL/ABB/SCHNEIDER/SIEMENS 

p) AC Drives : ABB / SIEMENS / L&T / ROCKWELL 

AUTOMATION/ SCHEIDER / HITACHI / 

NELCO 

q) Weighing system : SCHENCK/ 

SARTORIOUS/TRANSWEIGH 

r) Encoders : HUBNER 

s) Proximity & Photo : ROCKWELL/SCHNEIDER/SIEMENS 

Electric sensor 


----------------------------------------------------------------------------------------------------------------- 




27.0 List of drawings. 

Sl. 






These drawings shall be furnished by the tenderer during detail 

engineering. Approval of drawings from DSP/ MECON shall be responsibility of 

tenderer. 

Description Project Drg. No. Category 

Electrical 

schematic & 

DSP/HEC/14/02/01/COB- 

43B/DE/00010 

1 

2 

BOM 

GA of Control 

Panel DSP/HEC/14/02/01/COB- 

43B/DE/00011 

3 

4 

GA of Control 

Desk 

GA of PLC panel 

including HMI 


43B/DE/00012 


5 

6 

7 

GA of Local 

Control 

Post 

GA of Terminal 

Box 

Motor GA 

Drawing & data 

sheet with curve 

43B/DE/00013 


43B/DE/00014 


43B/DE/00015 


8 

9 

DC Brake GA 

Drawing 

Brake Rectifier 

Panel, 

GA, BOM & 

schematic 

43B/DE/00016 


43B/DE/00017 


43B/DE/00018 

10 Cable Selection 

Chart 


43B/DE/00019 

11 

12 

Data Sheet of all DSP/HEC/14/02/01/COBcables 

43B/DE/00020 

Data Sheet of 

lighting fixtures DSP/HEC/14/02/01/COB- 

13 

43B/DE/00021 

UPS-GA, 

schematic & 

BOM with battery DSP/HEC/14/02/01/COB- 

43B/DE/00022 

Approval 

Approval 

Approval 

Approval 

Approval 

Approval 

Approval 

Approval 

Approval 

Approval 

Approval 

Approval 

Approval 


----------------------------------------------------------------------------------------------------------------- 




sizing 

14 Data Sheet of 

Limit 

Switches 

(Proximity 

switches) 

15 Data Sheet of 

Laptop 

& Printer 






43B/DE/00023 

16 PLC I/O List 


43B/DE/00024 


43B/DE/00030 

17 Equipment 

Layout drgs DSP/HEC/14/02/01/COB- 

43B/DE/00031 

18 

19 

20 

21 

Cable layout 

drgs. 

External 

connection 

diagram 

Cable Schedule 

Control 

philosophy 


43B/DE/00032 


43B/DE/00033 


43B/DE/00034 


43B/DE/00035 

1.0 SCHEDULES 

SCHEDULE-1 

1.1 LIST OF COMMISSIONING SPARES 

Approval 

Approval 

Reference 

Reference 

Reference 

Reference 

Reference 

Reference 

SL.NO. EQUIPMENT DESCRIPTION OF SPARE QUANTITY 

REQUIRED REMARK 

S 


----------------------------------------------------------------------------------------------------------------- 




1 

2 

3. 

4. 

5. 

6. 

7. 

Contactor Coil 

Push Button 

Bulb for signal 

lamp 

Proximity switch 

AC incoming 

fuse for VVVF 

drive 

DC Link Fuse for 

VVVF drive 

Input/Output 

card 





1 no for each 

rating 

2 nos. 

5 nos. 

2 nos. 

1 set for each 

rating 


rating 


rating 


----------------------------------------------------------------------------------------------------------------- 








SCHEDULE-2 

1.2 SPECIAL TOOLS, TACKLES AND INSTRUMENTS 

SL.NO 

. 

NAME OF 

EQUIPMENT 

DESCRIPTION OF 

TOOLS/TACKLES/ 

INSTRUMENTS. 

QUANTITY 

RECOMMENDE 

D 

1 2.5 kV Hand wound megger 1 no 

2 3 ½” Digital Multimeter 1 no 

3 Laptop with latest 

configuration and licenced 

software. 

1 no 


----------------------------------------------------------------------------------------------------------------- 


PHONE: 0651 2401278, FAX: 0651 2401166, EMAIL: pksingh@hecltd.com 

REMARK 

S 

NOTE:- 

The above list is indicative. The Tenderer shall provide the complete list 

during BE/DE stage.






SCHEDULE-3 

FORMAT FOR LT MOTOR DATA SHEET 

1. MAKE : 

2. DRIVEN EQUIPMENT TAG NO. : 

3. 

4. 

MOTOR TAG NO. 

QUANTITY 

: 

: 

5. 

6. 

VOLTAGE WITH VARIATION : 

NO. OF PHASES/CONNECTION/ : 

NO. OF TERMINALS 

7. 

8. 

FREQUENCY WITH VARIATION : 

FAULT LEVEL (MVA) & DURATION : 

9. 

10. 

MOTOR TYPE & DUTY 

KW RATING/POLE 

: 

: 

* AT 40 DEG. C. : 

* AT SPECIFIED AMBIENT TEMP : 

WITH DERATING. 

* BHP/BKW OF DRIVEN EQPT. : 

AT RATED LOAD 

11. FRAME SIZE/MOUNTING : 

12. INSULATION CLASS WITH TEMP. : 

RISE 

13. ENCLOSURE TYPE : 

14. FULL LOAD SPEED : 

15. FULL LOAD TORQUE (FLT) : 

16. STARTING TORQUE AS % OF FLT : 

17. PULLOUT TORQUE AS % OF FLT : 

18. FULL LOAD CURRENT (FLC) : 

19. STARTING CURRENT AS % OF : 

FLC 

20. STARTING TIME ON RATED LOAD 

* AT RATED VOLTAGE : 

* AT 75 % OF RATED VOLTAGE : 

21. LOCKED ROTOR WITHSTAND 

TIME 

* COLD : 


----------------------------------------------------------------------------------------------------------------- 








* HOT : 

22. DIRECTION OF ROTATION : 

23. GD SQUARE OF MOTOR : 

24. GD SQUARE OF DRIVEN EQPT. : 

25. POWER FACTOR AT 

* 50 % LOAD : 

* 75 % LOAD : 

* 100 % LOAD : 

26. EFFICIENCY AT 

* 50 % LOAD : 

* 75 % LOAD : 

* 100 % LOAD : 

27. SPACE HEATER WATTS/VOLTS : 

28. TERMINAL BOX TYPE & : 

NO. OF TERMINALS 

29. FOR SLIP RING MOTORS 

* TYPE AND NO. OF RTDs 

FOR WINDINGS : 

* STATOR/ROTOR TIME : 

CONSTANT 

* ROTOR CURRENT AT FULL : 

LOAD 

* ROTOR VOLTAGE 

* ROTOR RESISTANCE 

: 

: 

30. NO. OF STARTS PER HOUR 

31. COOLING 

: 

: 

32. APPLICABLE STANDARD : 

33. APPLICABLE SPECIFICATION : 

34. LOCATION : 

35. HAZARDOUS AREA : 

CLASSIFICATION 

36. BEARING TYPE NO. : 

37. LUBRICATION TYPE : 

38. CABLE SIZE : 

39. WEIGHT IN KG. : 

40. G.A., DIMENSIONS & MOUNTING : YES/NO 

DETAIL DRAWINGS ENCLOSED 

41. DETAIL DRAWINGS FOR : 

TERMINAL YES/NO 


----------------------------------------------------------------------------------------------------------------- 




BOX 

42. PERFORMANCE 





CHARACTERISTIC CURVES 

VIZ. SPEED V/S CURRENT & 

SPEED 

V/S TORQUE ENCLOSED 

: YES/NO 


----------------------------------------------------------------------------------------------------------------- 








SCHEDULE-4 

STANDARD SPECIFICATION FOR PROGRAMMABLE LOGIC 

CONTROLLER 

PROGRAMMABLE LOGIC CONTROLLERS: 

Monitoring and control of Oven Machines operation shall be 

Programmable Logic Controller (PLC) based. 

The equipment shall confirm to the standards developed by the Inter 

plant standards for steel industry IPSS:2-07-015-93 and relevant 

standard of Bureau of Indian standards (BIS) as applicable. Where 

IPSS / BIS do not exist, the components of all equipment shall be de- 

signed, manufactured, assembled, tested and installed in accordance 

with the latest standards of IEEE/NEMA/IEC or National standards 

Institution of the country where they are manufactured. 

1.1 General Features 

The PLC system shall be so designed that it is completely reliable and 

availability of the system shall be better than 99%. The PLC system shall be 

most versatile, expandable, rugged, microprocessor based. The hardware 

shall be designed using advanced technology which shall bring a high level 

of capability, reliability and quality in the system. The PLC system shall 

comprise of processor I/O unit, multiplexers, A/D converters, communication 

electronics, CPU, Power Supply Modules, Memories for CPU; bus system, 

operators’ console with peripherals, interfacing equipment, marshalling / 

field termination racks, desks, panels etc. The input/output channels shall 

be provided with isolation. 

On-line replacement of any module shall be possible in such a way 

that the removal and addition of any module shall be possible without 

de-energizing the system. Further there shall not be any interruption in 

the system while replacing a faulty module except for the 

inputs/outputs which are being handled by the module. 


----------------------------------------------------------------------------------------------------------------- 








Operation of PLC shall be completely unaffected by a momentary 

power loss of the order of 20 milliseconds. 

The system shall have extensive set of self diagnostics hardware and 

software features with alarm facility for easy and fast maintenance. 

Diagnostics shall be required at local as well as in console level for 

identification of fault location. 

1.2 Environmental Classification 

The equipment shall be suitable for continuous duty under the 

following conditions: 

� Temperature while operating : 

lower limit : 0 degree C 

Upper limit : 55 degree C 

� Temperature while not operating (storage) 

lower limit : 20 degree C 

Upper limit : 70 degree C 

� Relative humidity 

- Daily average 80 to 90% (10 h) and 65 to 90% ( 16 h) 

- Maximum 98%, not occurring simultaneously with maximum 

temperature. 

1.3 Basic design particulars 

Power Supply Units 

� Plug in Modules as required for CPU / IO cards mounted on 

respective Racks 

� Power supply for CPU Rack 

� 24V Power supply Units for I/O interrogation and field instruments 

PLC System 

� Communication modules for Communication between PLCs, AC 

drives, DCS, Level2 system radio communication data exchange 

system and with field devices. 


----------------------------------------------------------------------------------------------------------------- 








� CPU Capable of handling PID functions and weighing and 

batching functions. 

Memory 

� EPROM / EEPROM 

� RAM with battery backup 

Input units 

- Discrete inputs 

- BCD inputs 

- Analog inputs ( configurable for mV, mA, T/C of various types, 

RTD) 

- Pulse inputs ( Incremental encoder / digital tacho) 

- Absolute encoder inputs ( gray code) 

Output units: 

- Discrete outputs for driving interposing output relays 

- BCD outputs 

- Analog outputs ( 4 – 20mA / 0 - 20mA) 

Timers From 10 milliseconds to few hours, Accuracy (+/-)0.1% 

Counters Count from 0000 to 9999 Up / Down 

1.4 Power Supply System 

� 415 V, 3 phase, 4 wire, 50 Hz solidly earthed neutral system. 

� Symmetrical fault level 50 kA, rms 

� Voltage variation : + 10% / -15% 

� Frequency variation: +4% / -6% 

1.4.1 Built-in power supply units 

� Suitable for the power supply system as specified above. 

� Insulation level 2.5 kV for 1 minute. 

� Protective features: 

� Surge voltage protection 

� Fuse protection in the input and output circuits 

� Electronic over current protection 


----------------------------------------------------------------------------------------------------------------- 








� Thermostat protection against over temperature 

� Independent units for the following :- 

� For CPU and associated electronic units 

� For sensing the status of input devices 

� For powering field transmitters through respective input cards 

� For driving outputs 

1.5 Central Processing Unit (CPU) 

� Modular and plug-in type 

� Central processor 32 or 16 bit microprocessor based 

� Single / multiple processors in coordination 

� Shall be capable of handling 30 % additional (future) I/Os over and 

above 20 % spares (installed) I/Os indicated in basic configuration 

diagram. 

� PLC shall be capable of handling weighing and batching loops 

� Maximum CPU loading shall be limited to 60 % for the intended 

applications 

� Scan time between 2 m sec to 5 m sec per one K instructions or 

better 

� Provision to latch desired outputs 

1.6 Memory 

1.6.1 Program memory: Formatted data shall be stored in EPROM / EEPROM 

or battery operated backed RAM. These memories shall be backed up 

by floppy disks. 

The general technical features of the memories shall be as 

follows: 


� Word length 8 bit/16 bit 

� Expandable in blocks 

� Minimum size 16K 

� Data and application program memory sized to have at least 

40% free memory space. 

� EEPROM / RAM with battery back-up 

� Back-up battery shall be as follows: 

� Rechargeable Ni-Cd batteries with necessary charging circuit / Lithium 

batteries of suitable capacity. 


----------------------------------------------------------------------------------------------------------------- 








� Able to sustain memories for a minimum of 14 days with no power 

applied to the controller. 

1.7 Process Input / Output (I/O) Units 

1.7.1 Input Units 

This unit shall provide the main interface between field devices, PLC and 

HMI system. This shall provide necessary slots / racks with complete wiring 

for installing the input / output cards for analog and logical I/Os and the 

controller connection. The field cables shall not be brought directly to the I/O 

cards. The same shall be routed through the field termination / marshalling 

racks. All wiring inside racks / cabinets / back of the panels shall be housed 

in covered nonflammable plastic raceways arranged to permit easy 

accessibility to various equipment for work and maintenance. The signal 

validity check, ambient temperature compensation for mV inputs from 

thermocouples and broken sensor check shall be necessarily a built-in 

feature for analog input cards. 20% I/O slots (installed) and 20% I/O cards 

(at least one card of each type minimum) shall be kept spare. 

Separate power supply unit shall be provided for individual I/O rack and 

processor. Suitable battery back-up shall be provided for volatile memory 

protection. 

Each I/O shall be electrically isolated from external control circuit by suitable 

means. The minimum isolation level between I/O and logic circuit shall be 

1500 V dc. 

Each I/O shall be protected against the reversal of polarity of the power 

supply voltage to I/O. 


� Insulation level of 1.5 kV 

� Individual fuse for each unit shall be provided for protection against 

cable fault/earth fault. 

� Input interrogation voltage 24V DC (built-in) preferable. 

� LED status indication 

Inputs shall be suitable for accepting the following: 

� Discrete input units shall have the following: 


----------------------------------------------------------------------------------------------------------------- 








- Time delay of about 10 millisecond to filter out noise and contact 

bounce. 

- Optocoupler to galvanically isolate each input device from the 

decision making logic of the controller 

� BCD input units suitable for four digit input 

� Pulse inputs ( Incremental encoder / digital tacho ) 

� Absolute / incremental encoder inputs 

� Analogue input units shall be as follows: 

- With necessary A/D converter having 12 /14 bit resolution. 

- Suitable for 4 - 20mA / 0 - 10V DC inputs ( with 24 V dc power supply 

facility in each card for the field transmitters, excepting one input card 

where this loop power supply facility is not required) 

- Suitable for PT100 2- wire / 3 wire 

- With insulation level of 1.5 kV 

- Each input shall be galvanically isolated. 

1.7.2 Output Units 


� Discrete output units shall be as follows: 

- Isolated output with two separate terminals for each output. 

- All outputs shall be through separate relays rated for 24V DC, 2A, 50 

Hz (15A for 50 milli-second to take care of the in rush current of the 

contactor coil). 

- Galvanically isolated by opto coupler 

- With LED status indication 

- With insulation level of 1.5 KV 

- Output relays shall have surge suppressor across them. Card mounted 

relays are not acceptable. 

� BCD output units shall be as follows: 

- Suitable for four digit output 

- Rated to drive seven segment displays used 


� Analog outputs shall be as follows: 


----------------------------------------------------------------------------------------------------------------- 








- Suitable for 4 - 20mA / 0 - 10V outputs 

- With necessary D/A converters having 12/14 bit resolution 


- Each output shall be galvanically isolated. 

1.8 Programming Unit 

� Laptop shall be provided for programming. 

� With facility for loading the programme developed on EPROM and CD. 

� Capable of ON line & OFF line programme development with 

necessary hardware interface and software. 

� Facility for simulation test and programme debugging with necessary 

software. 

1.9 Self diagnostic features 

� Parity errors, cycle errors and under voltage 

� Failure in central processor unit, memory and power supply. 

� Communication failures – all types 

� Indication of type of failure 

� Automatic turning OFF of all outputs or optionally holding of 

all outputs in their last state on failure detection. 

1.10 Terminations 

� All inputs and output wired upto easily accessible terminal blocks 

rated for 660V. 

� Screened cables for milli-Volt signals from I/O rack to terminal block. 

� Compensating cables for thermocouple signals from I/O rack to 

terminal block (with copper terminals). 

� Suitable for terminating upto 2.5sq. mm. copper conductor industrial 

control cables. 

� Fuse terminals for all output signals. 

1.11 Additional Features 

� Fully programmed 

� Connection of field devices with input units through ordinary multi 

core copper control cables. 


----------------------------------------------------------------------------------------------------------------- 








� Communication with computer in distributed hierarchical control 

system and operator consoles/display units. 

� Printers to get hard copy of the programme developed / process 

information / reports. 

1.12 Earthing 

Separate earthing bus for power / panel earthing and electronic 

earthing shall be provided. 

Electronic earthing bus shall be suitably insulated. Earthing 

requirements / earthing schemes for the equipment supplied shall be 

clearly indicated in appropriate drawings. 

1.13 Special Features 

i) The PLC system shall be immune to the following: 

- Radio frequency interference 

- Electromagnetic interference 

- Power system spikes 

The methods and standards followed for these features shall be 

furnished along with the tender. 

1.14 Other features 

� Test sockets on input modules for input simulation 

� Suitability for On-line replacement of I/O cards without switching of 

power supply 

� Switch to disable all outputs of the controller during startup/debugging 

� Fuse failure indication for outputs 

� Provision to connect VDU/Printer for alarm annunciation to accept set 

points, data display and logging 

� mA Ammeters to be mounted on the front panel for leakage current 

measurement during earth fault of input and output power bus . 

2.0 Constructional Features 


----------------------------------------------------------------------------------------------------------------- 








� Unitised construction 

� Sheet steel clad 

� Floor mounted, free standing and indoor type 

� cable entry provision from bottom 

� Panel illumination to be provided with door interlock limit 

switch 

� Dust and vermin proof 

� suitable anti-vibration pads to withstand vibrations 

� All modules plug-in type 

Enclosure 

� Conforming to IP-42 class, for equipment located in airconditioned 

room. 

Painting 

The sheet metal parts shall be subjected to the following pre-treatment 

before final painting. 

� Degreasing 

� Pickling for complete rust removed 

� Phosphating 

� Corrosion resistant primer painting. 

Final coats of spray paints shall be given as per shade No.631 as per IS 

5, 1995. 

3.0 Mounted Spares 

� Min of 20 % of I/O modules used with at least one module of each type 

for input and output shall be offered as spare for each programmable 

controller and the same shall be mounted and wired to the terminal 

block in the cubicle suitably. 

� Provision shall be provided with empty slots for future expansion for 

20% I/O modules. 

� Minimum 50 % spare memory capacity shall be built in the system 

after loading of application and system software. 


----------------------------------------------------------------------------------------------------------------- 








4.0 Miscellaneous requirements for programmable controllers 

� Programmable controllers shall be suitable for normal industrial 

environment though they shall be housed in air-conditioned rooms. 

� Table top mounted printer shall be provided. 

� Separate furniture (Printer tables) shall be provided for the above 

printers. 

� Cassettes/CDs loaded with frozen program of each PLC shall also be 

supplied. These shall be properly identified and housed on cubicle for 

ready use. 

5.0 SOFTWARE: 

a) PLC Programming software – 1 no for each machine. 

b) HMI software – 1 no for each machine. 

HUMAN MACHINE INTERFACE 

The Human Machine Interface shall be through the touch screen. PLC 

will be communicating directly with HMI. All the data updating taking 

place in the PLC will be updated in HMI. High resolution colour touch 

screen monitor will be provided. Sequence of various mechanism 

operation will be controlled and displayed on screen including alarms. 

i) Printer 

The workstation shall be connected with laser printer. 

The mounting of the printer shall be on separate tables. The tables 

shall be supplied along with printers. The noise of printers at 1 meter 

distance shall be less than 65 dB. 

Tests 

The following tests shall be carried out on PLCs in the presence of purchaser / representatives: 

� Visual inspection test. 

� Over all dimensions, component, mounting, and wiring. 


----------------------------------------------------------------------------------------------------------------- 








� Quantity checks for no. of I/O modules, peripherals etc. 

� Insulation test. 

� Temperature test (ageing test). 

� Mechanical vibration test. 

� Noise immunity test. 

� Bill of materials. 

� Functional tests : 

� Of CPU, programming unit, power supply, I/Os. 

� Test of all fault diagnostic features of PLC. 

� Checking of operation of each I/O port, timers. 

� Running of a test and actual programme, transfer of data to and 

from VDU key board unit and driving of printer. 

� Integrated functional test with all equipment and peripherals 

connected as per configuration diagram. 

Cables 

All necessary special cables with connectors required for 

interconnection of the different units of the above system shall be 

included in the scope of work. 


----------------------------------------------------------------------------------------------------------------- 








SCHEDULE-5 

STANDARD SPECIFICATION FOR VARIABLE VOLTAGE VARIABLE 

FREQUENCY CONVERTERS (AC DRIVES) 

VARIABLE VOLTAGE VARIABLE FREQUENCY DRIVE 

1.0 BASIC DESIGN PARTICULARS 

All VVVF Drives shall have Digital Control Technology with Vector control. 

VVVF shall communicate with PLC. 

� Input Voltage : 415V +10% to –15% , 3 phase neutral 

earthed system. 

� Input Frequency : 50 Hz +4%, -6% 

� Output Voltage : 3-Phase, 415 V max. at nominal input . 

� Output Frequency : Can be selected to suit the motor 

operating frequency range for constant torque 

and constant power 

1-50 Hz (Constant torque) 

50-100 Hz (Constant power) 

� Rated output current: Minimum 180% of full load RMS Current of 

motor/ group of motors for intended 

application 

1.1 Type of connections 

� Three phase frequency converters with rectification and inversion i.e. 

variable voltage and variable frequency output with current source / 

voltage source (PWM) inverters. 

� Line reactors /Isolation transformers for harmonic and noise 

suppression. 

1.2 Overload capacity 

� 150% of the rated inverter current for 1 minute following 100% load & 

to meet the drive overload capacity. 

1.3 Other Features 


----------------------------------------------------------------------------------------------------------------- 








� Efficiency more than 95% at full load. 

� Suitable to withstand vibrations more than 0.5 g. 

� Ramp rate : Linear acceleration and deceleration adjustable 

independently. 

� Set point for torque adjustable independently. 

2.0 Power components: 

The main power components of the VVVF equipment shall have the 

following equipment on incoming AC side: 

� Matching reactor. 

� AC line surge suppression network. 

� ACB/MCCB 

� Input contactors 

� Line contactors 

2.1 Load side 

� Filter network 

� Output side reactor. 

� Isolator and over-load relay for each motor. 

3.0 Principle Controls – Minimum Requirements : 

� IGBT Power Technology 

� PWM with Programmable career frequency 

� Reference speeds setter (SW selectable) 

� Torque / Power mode 

� Slip compensation control 

� V/f control 

� Speed feed back, as required 

� Current feed back 

� Dynamic current control 

� Programmable proactive current limit 

� Independently programmable acceleration & deceleration times ( 

Minimum 2 each) 

� Independently programmable Torque set points. 

� Zero speed / over speed monitor as applicable 

� Dynamic braking Chopper unit with resistance. 


----------------------------------------------------------------------------------------------------------------- 








� Facility to accept speed reference and other control from 

programmable controller through communication network. 

4.0 Protective features 

� AC line surge suppression network 

� Under voltage in supply network 

� Phase sequence protection and monitoring 

� Under voltage in DC link 

� Over voltage in DC link 

� Over speed monitor 

� Overload 

� Earth fault 

� Instantaneous over current 

� Transformer faults 

� Cooling fan failure 

� Stall monitor for motor 

� AC mains failure 

5.0 INPUTS 

ANALOG INPUTS 

(a) Frequency Setting 0-10 V DC ; 4 - 20 mA 

(b) Position feedback 

DIGITAL INPUTS 

(a) Reset : For fault reset & instantaneous 

output cutoff ( Normally Closed ) 

(b) Forward / Reverse run : Selectable individually. 

(c) Multistage speed / Torque : Four kinds of speed settings 

including main speed setting shall 

be selectable. 

(d) Jogging Operation : Selectable from 0 to 9.9 Hz Mode 

selection by digital input 

(e) Stop : Coast to zero command 

(f) Pulse inputs : From digital tacho / BCD from 

position encoder / Encoders 

(Incremental & absolute) 

6.0 OUTPUTS :- 


----------------------------------------------------------------------------------------------------------------- 




ANALOG OUTPUT 





(a) Frequency monitor : 0-10 V DC signal proportional to 

output frequency for driving analog 

meter. 

DIGITAL OUTPUTS 

(a) Fault alarm relay : Relay with change over contact 

available for annunciating inverter 

fault. 

(b) Drive running signal : output (24V DC) for driving 

externally connected relays. 

(c) Frequency arrival signal : Output (24V DC) for driving 

externally connected relays. 

(d) Annunciator outputs : Contact outputs for annunciating 

various inverter panel faults in 

lighted windows. 


� Floor mounted, free standing 


� Sheet steel clad 

- Minimum 2.5 mm thick for panels. 

- Minimum 2.0 mm thick for doors and side covers 

� ISMC 75 base channel at the bottom. 

� Suitable to withstand vibrations to be encountered in steel plant 

applications. 

� Provided with anti vibration Pads 

� Cubicles with illumination lamps, door switches, space heaters and 

adequate sockets for connecting instrument, soldering iron etc. 

� All control blocks plug-in-type with necessary test sockets. 

� Units shall be self contained and serviceable. 

8.0 Enclosure and Ventilation 

� Enclosure conforming to IP-42. 

� Units shall be provided with cooling fans and louvers at the bottom 

sides. All louvres shall have fine mesh behind them. 


----------------------------------------------------------------------------------------------------------------- 




9.0 Test 





� Ventilation through individual ventilation ducts, from bottom not 

acceptable. 

� Ambient temperature shall be 55ºC . 

a) The following tests shall be carried out at works in the presence of 

purchaser's representative: 

� Visual inspection 

� Insulation test 

� High voltage test 

� Functional test 

� Light load test 

� Full load and temperature rise test 

b) The following tests shall be performed at site : 

� Visual inspection 

� Insulation test 

� Functional test 

� Light load test 


----------------------------------------------------------------------------------------------------------------- 








SCHEDULE-6 

STANDARD SPECIFICATION FOR L T INVERTER DUTY MOTOR 

Sl.No. Parameters Description 

1.0 Type - AC Squirrel cage induction motor. 

- Inverter Duty 

2.0 Standard - IPSS 1-03-001/ IS 325 

- NEMA Standard MG1-1993 Part 31, or 

the latest revision in so far as it is 

applicable. 


A Frame size & rating - As per IS 325 

- 10:1 constant torque speed range 

motors may exceed frame standard 

by one frame rating. 

B Motor body Grey iron casting as per IS:210-1978 

C Motor Feet Integrally cast with the stator 

D Body Design - Prevent breakage or other failures 

due to vibrations normally 

encountered in heavy industries . 

- Motors shall be of weather proof 

construction. 

- Designed to operate in the humid air 

E Protection for Motor & 

Bearing 

stream . 

IP - 55 

(with canopy for motor) 

F Motor Shaft Shall be provided with an external 

recessed slinger at the drive end of the 

motor to provide additional (minimum 


----------------------------------------------------------------------------------------------------------------- 








IP-54) protection from moisture and 

foreign material. 

G Shaft ends & Extension - Cylindrical as per requirement 

- Shaft shall be extended for encoder / 

tacho. mounting, accordingly 

suitable hole shall be drilled and 

tapped . 

H Internal Encoder Motors with speed variation of 1000:1 at 

constant torque shall have internal built 

in encoder for speed feedback. 

I Bearing - Roller type bearing upto 5 kW . 

- Ball Bearing at NDE end for above 5 

kW. 

- All motors shall have fully regreasable, 

anti-friction bearings. 

- All motors shall have cast iron inner 

bearing caps. 

- Bearings shall be oversized . 

- All motors shall have a charged 

lubrication system to inhibit moisture 

condensation. 

- Standard motors shall have extended 

grease fittings on the opposite driveend 

to facilitate re-lubrication. Grease 

ports shall be located on the 

periphery of the motor end shield. 

- Motor shall be fitted with a shaft 

slinger or V ring seal on the drive end 

for a minimum of IP-54 protection (to 

help protection of bearing from 

ingress of dust, dirt or fluids) 


----------------------------------------------------------------------------------------------------------------- 




J Hazardous Area safety 

design 

4.0 Terminal box 





As per process requirement 

A Location RHS viewed from DE / On top 

B Suitability - 4 Core Aluminium Cable 

- The terminal box shall be oversize as 

compared to NEMA requirements. 

C Rotation 4 X 90 deg. 

D Earthing stud Inside Terminal Block 

E Miscellaneous - Shall be gasketed between the 

terminal box halves. 

- The conduit box shall be field 

convertible to cast iron. 

- External screws and bolts shall be 

grade five, hex heads and be plated to 

resist corrosion. 

5.0 Cooling - TEFC, Effective bi-directional 

- Motor with 1000:1 speed range and 

constant torque shall have external 

fan. 

- External fan motor shall be 3 phase , 

440 V AC 

- Thermistors shall be provided in the 

windings. 

6.0 Quality of operation 

A Vibration intensity - Shall be limited as per IS 12075-1986. 

- Shall not exceed .08 inches / second 

velocity. 

B Noise level As per IS: 12065-1987 


----------------------------------------------------------------------------------------------------------------- 




7.0 Electrical design 





A Power Supply 415 V +10% / -15%, 3-phase, 50 Hz + 4%/- 

6% , 

4-wire AC, 50 kA for 1 second, solidly 

earthed. 

B Starting Variable Frequency Drive 

C Service factor - 1.0 for VFD power . 

- 1.15 for sine wave power . 

D Peak transient voltage 1500 V 

E Minimum rise time 0.1 microsecond 

F Starting Torque 200 % rated torque for 1 minute below 

base speed 

G Constant horsepower 

operation 

1.5 times base speed . 

H Duty Application dependent 

I Max speed 

permissible 

150 % rated for 2 minutes 

J Derating for VFD As per above mentioned standard 

K Insulation - Minimum Class H 

- Insulation materials with additional 

phase insulating material, extra endturn 

bracing and Class H spike 

resistant wire. 

L Load Type Constant Torque / Variable Torque 

(As per application) 

M Space Heater - Out door motors above 45 kW 

- Indoor Motor above 110 kW 


----------------------------------------------------------------------------------------------------------------- 








N Temperature Rise Limited to Class F 

O No. of Poles 6 / 8 

8.0 Operating Characteristics 

A Operation with variation 

in the voltage or the 

frequency 

Motors shall operate successfully 

under running conditions at rated load 

with variation in the voltage or the 

frequency not exceeding the following 

conditions: 

+/-10% rated voltage at rated constant 

V/f ratio except for specific torque 

boost situations. 

Motors shall operate successfully 

under running conditions at rated load 

and V/f ratio when the voltage 

unbalance at the motor terminals does 

not exceed one percent. 

B Torques Motors shall meet or exceed the 

minimum locked rotor (starting) and 

breakdown torques specified in NEMA 

Standard MG1 Part 12 for Design B for 

the rating specified when on sine wave 

power. 

C Operating speed range - Zero to base speed in case of VT. 

- 1000: 1 for CT (with blower cooling) 

D Locked rotor (starting) 

currents 

- 10:1 , 6:1 , 4:1 for CT . 

Shall not exceed NEMA Design B values 

for the specified rating on 5:1 constant 

torque or less and variable torque 

motors. NEMA Design A values are 

allowed for 6:1 constant torque or 


----------------------------------------------------------------------------------------------------------------- 








higher value constant torque rated 

motors. 

Motors shall be capable of a 20 second 

stall at six times full load current 

without injurious heating to motor 

components. 

E Efficiency - Shall have a nameplate minimum and 

nominal full load efficiency for motors 

when tested in accordance with 

NEMA standard MG1 Part 12, IEEE 

Test Procedure 112 Method B, using 

accuracy improvement by segregated 

loss determination including stray 

load loss measurements. 

9.0 Motor location Outdoor / indoor installation. 

10.0 Painting For indoor motors: 

- Surface preparation shall be made by 

sand blasting or shot blasting to near 

white metal 

- After surface preparation two coats of 

air drying epoxy based red oxide zinc 

phosphate primer shall be applied. 

Dry film thickness of each coat shall 

be 30 microns minimum. 

- After primer has dried two coats of air 

drying epoxy based enamel paint 

shall be applied. Dry film thickness of 

each coat shall be 40 microns 

minimum. 

- The total thickness of painting shall 

thus be 140 microns. 


----------------------------------------------------------------------------------------------------------------- 








For outdoor motors: 

- Surface preparation shall be made by 

sand blasting or shot blasting to near 

white metal. 

- After surface preparation two coats of 

air drying epoxy based red oxide zinc 

phosphate primer shall be applied. 

Dry film thickness of each coat shall 

be 30 microns minimum. 

- One coat of air drying epoxy resin 

based intermediate paint shall be 

applied after primer. Dry film 

thickness of intermediate paint shall 

be 100 microns minimum. 

- After intermediate paint has dried two 

coats of air drying epoxy based 

enamel paint shall be applied. Dry 

film thickness of each coat shall be 40 

microns minimum. 

The total thickness of painting shall 

thus be 240 microns. 

11.0 Nameplate - Shall be of stainless steel and 

stamped per NEMA Standard MG1 

Part 10 and Part 31. 

- Nameplate information shall include 

as a minimum, the nominal efficiency 

value per NEMA Standard MG1 Part 

12, the bearing identification 

numbers, power factor, Torque values 

with speed range and amps for that 

torque value. 

- Nameplate also shall include Full 


----------------------------------------------------------------------------------------------------------------- 








Load Slip RPM, Magnetizing amps 

and (if included) encoder PPR and 

Voltage rating. 


----------------------------------------------------------------------------------------------------------------- 




1.1 GENERAL 





SCHEDULE-7 

STANDARD SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY 

SYSTEM 

Technical parameters for design 

Power supply system : 440 V, 50 Hz, 3 phase, 4 wire 

System neutral : Earthed 

Insulation level : 2.5 kV 

System short circuit level : 50 kA for 1 second 

Output Voltage : 240V, AC, 50 Hz. 

UPS system shall be of adequate capacity to cater for power 

requirement of the entire automation system. 

This shall include PLC panels, I/O Panels, Workstations, etc., located in 

operator’s room and various electrical rooms. 

This shall also include power supply for I/O interrogation, transmitter 

power supply (24V DC) for field instruments connected to PLC 

wherever applicable, etc. 

1.2 Basic particulars for design: 

Basic details: 

� Features and performance in line with IEEE 446 and configuration as 

per fig 45 of IEEE 446. 

� 125% of the rated output for 15 minutes 

� Suitable for connecting to a 415 V, 3 phase, 50 Hz, 4 wire, grounded 

neutral system with a symmetrical fault level of 50 kA rms. 

� Three / Single phase voltage and frequency controlled output, as 

required. 

� With isolating transformer, rectifier, inverter unit and necessary DC 

batteries. 

� Dual redundant system with automatic static bypass and common DC 

battery. 


----------------------------------------------------------------------------------------------------------------- 








� DC battery shall be sealed maintenance free Lead acid with plate cells 

type. 

� Battery shall be suitable to maintain the power supply for at least 30 

minutes in the event of mains failure. 

� 25% overload condition to be considered for battery sizing. 

� Electronic bypass switch to connect the system to the mains supply 

without interruption to the load in the event of inverter failure. 

� Necessary distribution board in different areas for distribution of 

power from UPS output to individual consumers. 

Permissible variations: 

Mains power supply system 

� Voltage : ± 10 % 

� Frequency : ± 5% 

Output of the uninterrupted power supply system while 

delivering a load of its rated capacity 

� Voltage : (+/-) 3 % 

� Frequency : (+/-) 0.1 % 

� Harmonic distortion: Max. 2 % 

Transformer 

� Rating suitable for the application 

� Dry type , with class H insulation 

� + 2.5% with tappings on primary 

Rectifier 

� Dual rectifier with each unit rated for supplying both inverter load 

and battery charger load. 

� Rectifier unit shall consist of minimum six pulse bridge 

connection 

� With necessary smoothing reactor and filters 

� Automatic boost and float charging control 

Protective features: 

� Maximum current limiting 


----------------------------------------------------------------------------------------------------------------- 








� Automatic reduction of current limit in the event of cooling fan 

failure 

� Boost charging and float charging current limiting 

� Earth fault monitoring and protection 

� Thermal overload protection 

Indications: 

� Rectifier ON 

� Battery run out timer/counter 

� Low battery voltage or blown battery fuse 

� High battery voltage 

� Charging failure 

� Failure in line voltage or auxiliary supply 

� Blown fuse, single phasing or over current 

� Fan failure 

� Battery on float charge /boost charge. 

� Inverter On 

� Inverter reserve synchronised 

Batteries: 

Batteries for UPS shall be lead acid sealed maintenance free type. The 

Ampere Hour rating of the battery shall be adequate to supply the 

inverters on full load for 30 minutes back up. Batteries shall be 

installed in suitable metallic enclosure and located near UPS. 

Inverter & Controls: 

Construction details: 

� Unitised construction 

� Free standing, floor mounted and indoor type 

� Provided with anti vibration Pads 


� Sheet steel clad , Min 2.0 mm thick for panels & : Min 1.6 mm 

thick for doors and side covers 

� With illumination lamps, door switches, space heaters and 

sockets for soldering 

� All control block plug-in type with test sockets 

� Units shall be self contained and serviceable 


----------------------------------------------------------------------------------------------------------------- 








Basic Features: 

� IGBT Based. 

� With input circuit consisting of battery contactor, filter and 

smoothing reactor 

� Dc/dc converter for voltage control 

� Inverter proper and control electronics 

� Series reactor and parallel filter 

� Output transformer. 

� Static by-pass 

� Switch load automatically to the reserve power supply on 

fault 

� Fast acting inverter contactor to connect the inverter output 

to the load. 

� High speed fuses 

� The changeover within 20 ms. 

Indication 

� Load on inverter 

� Load on By-pass 

� Reserve within limits 

Meters 

� Output voltage - Phase-neutral & between phases 

� Output frequency 

� Ammeter in each phase 

� Battery current and voltage with indication of status in charge or 

discharge 

Alarms 

� Reserve out of limits 

� Load on reserve 

� Static switch off 

Protection against the following: 

� Abnormal output voltage 

� Abnormal link voltage 

� Over current on output 

� Over current on input or commutating failure 

� Low battery voltage 

� High transformer temperature 


----------------------------------------------------------------------------------------------------------------- 




� Auxiliary supply failure 

� Fan failure 

� Logic failure 

� Clock failure 

1.3 Enclosure and ventilation 





� Enclosure conforming to IP-41 class 

� Units shall be provided with cooling fans and louvers at the 

bottom sides. 

� Individual ventilation ducts for each unit shall be provided. 

1.4 UPS DISTRIBUTION BOARD 

Suitable UPS distribution board with sufficient feeders to supply 

individual PLC panels, I/O Panels, Workstations etc. 

20% spare supply feeders shall be considered for future use. 


----------------------------------------------------------------------------------------------------------------- 




SCHEDULE-8 





8.4 LIST OF RECOMMENDED SPARES FOR TWO YEARS OPERATION & 

MAINTENANCE 

SL.NO 

. 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

EQUIPMENT DESCRIPTION OF 

SPARE 

ELECTRICAL 

Contactor Coil 

Push Button 

Bulb for signal 

lamp 

Proximity switch 

Limit Switches 

AC incoming fuse 

for VVVF drive 

Control cards for 

VVVF drive 

Digital input 

module 

Digital output 

module 

Analog output 

module 

DC Link Fuse for 

QUANTIT 

Y 

INSTALLE 

D 

QUANTIT 

Y 

RECOMM 

ENDED 

2 nos. for 

each rating 

4 nos. 

10 nos. 

4 nos. 

1 no. of 

each type 

1 set for 

each rating 

1 set 

1no. 

1no. 

1no. 

2 sets for 

each rating 

Page 99 of 100 

----------------------------------------------------------------------------------------------------------------- 

VVVF drive 


PHONE: 0651 2401278, FAX: 0651 2401166, EMAIL: pksingh@hecltd.com 

REMARKS






NOTE:- 

The above list is indicative. The Tenderer shall provide the complete 

list during BE/DE stage. 

Page 100 of 100 

-----------------------------------------------------------------------------------------------------------------

Tender Enquiry No HMB/CED/PUR/99/04/10/017/LTE-060 - Heavy ...

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?